sv1za
As filed with the Securities and Exchange Commission on
January 12, 2007
Registration
No. 333-137623
SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Pre-Effective Amendment No. 3
to
Form S-1
REGISTRATION STATEMENT UNDER THE SECURITIES ACT OF 1933
KAISER ALUMINUM CORPORATION
(Exact Name of Registrant as Specified in Its Charter)
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Delaware |
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3334 |
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94-3030279 |
(State or Other Jurisdiction of
Incorporation or Organization) |
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(Primary Standard Industrial
Classification Code Number) |
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(I.R.S. Employer
Identification Number) |
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27422 Portola Parkway, Suite 350
Foothill Ranch, California 92610-2831
(949) 614-1740
(Address, Including Zip Code, and Telephone Number,
Including Area Code, of Registrants Principal Executive
Offices) |
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John M. Donnan
Vice President, General Counsel and Secretary
Kaiser Aluminum Corporation
27422 Portola Parkway, Suite 350
Foothill Ranch, California 92610-2831
(949) 614-1740
(Name, Address, Including Zip Code, and Telephone
Number,
Including Area Code, of Agent for Service) |
With a copy to:
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Troy B. Lewis
Mark T. Goglia
Jones Day
2727 North Harwood Street
Dallas, Texas 75201-1515
Telephone: (214) 220-3939
Facsimile: (214) 969-5100 |
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Joseph A. Hall
Davis Polk & Wardwell
450 Lexington Avenue
New York, New York 10017
Telephone: (212) 450-4000
Facsimile: (212) 450-4800 |
Approximate date of commencement of proposed sale to the
public: As soon as practicable on or after the effective
date of this Registration Statement.
If any of the securities being registered on this form are to be
offered on a delayed or continuous basis pursuant to
Rule 415 under the Securities Act of 1933 (the
Securities Act), check the following
box. o
If this form is filed to register additional securities for an
offering pursuant to Rule 462(b) under the Securities Act,
please check the following box and list the Securities Act
registration statement number of the earlier effective
registration statement for the same
offering. o
If this form is a post-effective amendment filed pursuant to
Rule 462(c) under the Securities Act, check the following
box and list the Securities Act registration statement number of
the earlier effective registration statement for the same
offering. o
If this form is a post-effective amendment filed pursuant to
Rule 462(d) under the Securities Act, check the following
box and list the Securities Act registration statement number of
the earlier effective registration statement for the same
offering. o
The Registrant hereby amends this Registration Statement on
such date or dates as may be necessary to delay its effective
date until the Registrant shall file a further amendment which
specifically states that this Registration Statement shall
thereafter become effective in accordance with Section 8(a)
of the Securities Act or until this Registration Statement shall
become effective on such date as the Securities and Exchange
Commission, acting pursuant to said Section 8(a), may
determine.
The
information in this prospectus is not complete and may be
changed. We may not sell these securities until the registration
statement filed with the Securities and Exchange Commission is
effective. This prospectus is not an offer to sell these
securities and it is not soliciting an offer to buy these
securities in any state where the offer or sale is not
permitted.
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PRELIMINARY PROSPECTUS |
Subject to Completion |
January 12, 2007 |
5,461,870 Shares
Common Stock
This is an offering of common stock of Kaiser Aluminum
Corporation. All of the shares of common stock are being sold by
the selling stockholders named in this prospectus. We will not
receive any proceeds from the sale of the shares by the selling
stockholders.
Our common stock is traded on the Nasdaq Global Market under the
symbol KALU. On January 11, 2007, the last
reported sales price of our common stock on the Nasdaq Global
Market was $59.25 per share. Our common stock is subject to
certain transfer restrictions that potentially prohibit or void
transfers by any person or group that is, or as a result of such
a transfer would become, a 5% stockholder.
Investing in our common stock involves risks. Before buying
any shares you should carefully read the discussion of material
risks of investing in our common stock contained in Risk
Factors beginning on page 10 of this prospectus.
Neither the Securities and Exchange Commission nor any state
securities commission has approved or disapproved of these
securities or determined if this prospectus is truthful or
complete. Any representation to the contrary is a criminal
offense.
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Per share | |
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Total | |
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Public offering price
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Underwriting discounts and commissions
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Proceeds, before expenses, to the selling stockholders
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The underwriters may also purchase up to an additional
819,280 shares of common stock from one of the selling
stockholders at the public offering price, less underwriting
discounts and commissions, within 30 days from the date of
this prospectus to cover over-allotments, if any. If the
underwriters exercise this option in full, the total
underwriting discounts and commissions will be
$ and
total proceeds, before expenses, to the selling stockholders
will be
$ .
Delivery of the shares of common stock will be made on or
about ,
2007.
The underwriters are offering the common stock as set forth
under Underwriting.
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UBS Investment Bank |
Bear, Stearns & Co. Inc. |
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Lehman Brothers |
Lazard Capital Markets |
The date of this prospectus
is ,
2007
You should rely only on the information contained in this
prospectus or to which we have referred you. We have not
authorized anyone to provide you with information that is
different. This document may be used only where it is legal to
sell our common stock. The information contained in this
prospectus is current only as of the date of this prospectus,
regardless of the time of delivery of this prospectus or any
sale of our common stock.
TABLE OF CONTENTS
Kaiser Aluminum, Kaiser
Selecttm,
Kaiser Precision
Selecttm,
Kaiser Precision
Rodtm,
our logo and certain other names of our products are our
trademarks, trade names or service marks. Each trademark, trade
name or service mark of any other company appearing in this
prospectus belongs to its holder.
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Prospectus summary
This summary highlights information contained elsewhere in
this prospectus. This summary does not contain all of the
information that may be important to you. You should read this
entire prospectus carefully, including the risks discussed under
Risk factors and the financial statements and notes
thereto included elsewhere in this prospectus. In this
prospectus, all references to (1) Kaiser,
we, us, the company and
our refer to Kaiser Aluminum Corporation and its
subsidiaries unless the context otherwise requires or where
otherwise indicated; (2) the Union VEBA Trust
refers to the voluntary employees beneficiary association
trust, or VEBA, that provides benefits for certain eligible
retirees represented by certain unions and their spouses and
eligible dependents; (3) the Salaried Retiree VEBA
Trust refers to the VEBA that provides benefits for
certain other eligible retirees and their surviving spouses and
eligible dependents; and (4) the Asbestos PI Trust
refers to the Kaiser Aluminum & Chemical Corporation
Asbestos Personal Injury Trust.
OUR COMPANY
We are a leading independent fabricated aluminum products
manufacturing company with 2005 net sales of approximately
$1.1 billion. We were founded in 1946 and operate 11
production facilities in the United States and Canada. We
manufacture rolled, extruded, drawn and forged aluminum products
within three product categories consisting of aerospace and high
strength products (which we refer to as Aero/ HS products),
general engineering products and custom automotive and
industrial products.
We produced and shipped approximately 482 million pounds of
fabricated aluminum products in 2005, which comprised 86% of our
total net sales. Of our total fabricated product shipments in
2005, approximately 29% were Aero/ HS products, approximately
44% were general engineering products and the remaining
approximately 27% consisted of custom automotive and industrial
products. Of our total fabricated products net sales in 2005,
approximately 38% were Aero/ HS products, approximately 38% were
general engineering products and the remaining approximately 24%
consisted of custom automotive and industrial products.
In order to capitalize on the significant growth in demand for
high quality heat treat aluminum plate products in the market
for Aero/ HS products, we have begun a major expansion at our
Trentwood facility in Spokane, Washington. We anticipate that
the Trentwood expansion will significantly increase our aluminum
plate production capacity and enable us to produce thicker gauge
aluminum plate. The $105 million expansion will be
completed in phases, with one new heat treat furnace currently
operating at full production, a second such furnace currently
operational and expected to reach full production no later than
early 2007 and a third such furnace becoming operational in
early 2008. A new heavy gauge stretcher, which will enable us to
produce thicker gauge aluminum plate, will also become
operational in early 2008.
We have long-standing relationships with our customers, which
include leading aerospace companies, automotive suppliers and
metal distributors. We strive to tightly integrate the
management of our fabricated products operations across multiple
production facilities, product lines and target markets in order
to maximize the efficiency of product flow to our customers. In
our served markets, we seek to be the supplier of choice by
pursuing
best-in-class
customer satisfaction and offering a product portfolio that is
unmatched in breadth and depth by our competitors.
The price we pay for primary aluminum, the principal raw
material for our fabricated aluminum products business, consists
of two components: the price quoted for primary aluminum ingot
on the London Metals Exchange, or the LME, and the
Midwest Transaction Premium, a premium to LME reflecting
domestic market dynamics as well as the cost of shipping and
warehousing. Because aluminum prices are volatile, we manage the
risk of fluctuations in the price of primary aluminum through a
combination of pricing policies, internal hedging and financial
derivatives. Our three principal pricing mechanisms are as
follows:
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Spot
price. Some of our
customers pay a product price that incorporates the spot price
of primary aluminum in effect at the time of shipment to a
customer. This pricing mechanism typically allows us to pass
commodity price risk to the customer.
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Index-based
price. Some of our
customers pay a product price that incorporates an index-based
price for primary aluminum such as Platts Midwest price
for primary aluminum. This pricing mechanism also typically
allows us to pass commodity price risk to the customer.
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Fixed
price. Some of our
customers pay a fixed price. During 2003, 2004, 2005 and the
nine months ended September 30, 2006, approximately
97.6 million pounds (or approximately 26%),
119.0 million pounds (or approximately 26%),
155.0 million pounds (or approximately 32%) and
153.0 million pounds (or approximately 38%), respectively,
of our fabricated products were sold at a fixed price. We bear
commodity price risk on fixed-price contracts, which we normally
hedge though a combination of financial derivatives and
production from Anglesey Aluminium Limited, described below.
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In addition to our core fabricated products operations, we have
a 49% ownership interest in Anglesey Aluminium Limited, an
aluminum smelter based in Holyhead, Wales. Anglesey has produced
in excess of 140,000 metric tons for each of the last three
fiscal years, of which 49% is available to us. We sell our
portion of Angleseys primary aluminum output to a single
third party at market prices. During 2005, sales of our portion
of Angleseys output represented 14% of our total net
sales. Because we also purchase primary aluminum for our
fabricated products at market prices, Angleseys production
acts as a natural hedge for our fabricated products operations.
Please see Risk factors The expiration of the power
agreement for Anglesey may adversely affect our cash flows and
affect our hedging programs for a discussion regarding the
potential closure of Anglesey, which could occur as soon as 2009.
OUR COMPETITIVE STRENGTHS
We believe that the following competitive strengths will enable
us to enhance our position as one of the leaders in the
fabricated aluminum products industry:
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Leading market positions in
value-added niche markets for fabricated
products. We have
repositioned our business to concentrate on products in which we
believe we have strong production capability, well- developed
technical expertise and high product quality. We believe that we
hold a leading market share position in niche markets that
represented approximately 85% of our 2005 net sales from
fabricated aluminum products. Our leading market position
extends throughout our broad product offering, including plate,
sheet, seamless extruded and drawn tube, rod, bar, extrusions
and forgings for use in a variety of value-added aerospace,
general engineering and custom automotive and industrial
applications.
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Well-positioned growth
platform. We have
substantial organic growth opportunities in the production of
aluminum plate, extrusions and forgings. We are in the midst of
a $105 million expansion of our Trentwood facility that
will allow us to significantly increase production capacity and
enable us to produce thicker gauge aluminum plate. We also have
the ability to add presses and other manufacturing equipment at
several of our current facilities in order to increase extrusion
and forging capacity. Additionally, we believe our platform and
financial strength provide us with flexibility to create
additional stockholder value through selective acquisitions.
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Supplier of
choice. We pursue
best-in-class
customer satisfaction through the consistent, on-time delivery
of high quality products on short lead times. We offer our
customers a portfolio of both highly engineered and industry
standard products that is unmatched in breadth and depth by most
of our competitors. Our continuous improvement culture is
grounded in our production system, the Kaiser Production System,
which involves an integrated utilization of application and
advanced process engineering and business improvement
methodologies such as lean enterprise, total productive
maintenance and six sigma. We believe that our broad product
portfolio of highly engineered products and the Kaiser
Production System, together with our established record of
product innovation, will allow us to remain the supplier of
choice for our customers and further enhance our competitive
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Blue-chip customer base and
diverse end markets.
Our fabricated products customers include leading aerospace
companies, automotive suppliers and metal distributors, such as
A.M. Castle-Raytheon, Airbus Industrie, Boeing, Bombardier,
Eclipse Aviation, Reliance Steel & Aluminum and
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Transtar-Lockheed Martin. We have long-term relationships with
our top customers, many of which we have served for decades. Our
customer base spans a variety of end markets, including
aerospace and defense, automotive, consumer durables, machinery
and equipment, and electrical. |
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Financial strength. We have little debt and significant
liquidity as a result of our recent chapter 11 bankruptcy
reorganization. We also have net operating loss carry-forwards
and other significant tax attributes that may reduce our future
cash payments of U.S. income tax. We previously disclosed
our belief that these tax attributes could together offset in
the range of $555 to $900 million of otherwise taxable
income, and we currently anticipate that, upon completion of our
2006 income tax return analysis, the amount of our tax
attributes as of December 31, 2006 will likely be in the
upper half of that range. |
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Strong and experienced management. The members of our
senior management team have, on average, 20 years of
industry work experience, particularly within the areas of
operations, technology, marketing and finance. Our management
team has repositioned our fabricated products business and led
us through our recent chapter 11 bankruptcy reorganization,
creating a focused business with financial and competitive
strength. |
OUR STRATEGY
Our principal strategies to increase stockholder value are to:
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Pursue organic
growth. We will
continue to utilize our manufacturing platform to increase
growth in areas where we are well-positioned such as aluminum
plate, forgings and extrusions. For instance, we anticipate that
the expansion of our Trentwood facility will enable us to
significantly increase our production capacity and enable us to
produce thicker gauge aluminum plate, allowing us to capitalize
on the significant growth in demand for high quality heat treat
aluminum plate products in the market for Aero/ HS products.
Further, our well-equipped extrusion and forging facilities
provide a platform to expand production as we take advantage of
opportunities and our strong customer relationships in the
aerospace and industrial end markets.
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Continue to differentiate our
products and provide superior customer
support. As part of
our ongoing supplier of choice efforts, we will continue to
strive to achieve
best-in-class
customer satisfaction. We will also continue to offer a broad
portfolio of differentiated, superior-quality products with high
engineering content, tailored to the needs of our customers. For
instance, our unique
T-Form®
sheet provides aerospace customers with high formability as well
as requisite strength characteristics, enabling these customers
to substantially lower their production costs. Additionally, we
believe our Kaiser
Select®
Rod established a new industry benchmark for quality and
performance in automatic screw applications. By continually
striving for
best-in-class
customer satisfaction and offering a broad portfolio of
differentiated products, we believe we will be able to maintain
our premium product pricing, increase our sales to current
customers and gain new customers, thereby increasing our market
share. |
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Continue to enhance our
operating
efficiencies. During
the last five years, we have significantly reduced our costs by
narrowing our product focus, strategically investing in our
production facilities and implementing the Kaiser Production
System. We will continue to implement additional measures to
enhance our operating efficiency and productivity, which we
believe will further decrease our production costs.
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Maintain financial
strength. We intend
to employ debt judiciously in order to remain financially strong
throughout the business cycle and to maintain our flexibility to
capitalize on growth opportunities.
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Enhance our product portfolio
and customer base through selective
acquisitions. We may
seek to grow through acquisitions and strategic partnerships. We
will selectively consider acquisition opportunities that we
believe will complement our product portfolio and add long-term
stockholder value.
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REORGANIZATION
Between the first quarter of 2002 and the first quarter of 2003,
Kaiser and 25 of our then-existing subsidiaries filed voluntary
petitions for relief under chapter 11 of the United States
Bankruptcy Code. Pursuant to our plan of reorganization, we
emerged from chapter 11 bankruptcy on July 6, 2006.
Our plan of reorganization allowed us to shed significant legacy
liabilities, including long-term indebtedness, pension
obligations, retiree medical obligations and liabilities
relating to asbestos and other personal injury claims. In
addition, prior to our emergence from chapter 11
bankruptcy, we sold all of our interests in bauxite mining
operations, alumina refineries and aluminum smelters, other than
our interest in Anglesey, in order to focus on our fabricated
aluminum products business, which we believe maintains a
stronger competitive position and presents greater opportunities
for growth.
INDUSTRY OVERVIEW
The aluminum fabricated products market is broadly defined as
the markets for flat-rolled, extruded, drawn, forged and cast
aluminum products, which are used in a variety of end-use
applications. We participate in certain portions of the markets
for flat-rolled, extruded/drawn and forged products focusing on
highly engineered products for aerospace and high strength,
general engineering and custom automotive and industrial
applications. The portions of markets in which we participate
accounted for an estimated 20% of total North American shipments
of aluminum fabricated products in 2005.
We have chosen to focus on the manufacture of aluminum
fabricated products primarily for aerospace and high strength,
general engineering and custom automotive and industrial
applications.
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Products sold for aerospace and
high strength applications represented 29% of our 2005
fabricated products shipments. We offer various aluminum
fabricated products to service aerospace and high strength
customers, including heat treat plate and sheet products, as
well as cold finish bars and seamless drawn tubes. Heat treated
products are distinguished from common alloy products by higher
strength, fracture toughness and other desired product
attributes.
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Products sold for general
engineering applications represented 44% of our 2005 fabricated
products shipments. This market consists primarily of
transportation and industrial end customers who purchase a
variety of extruded, drawn and forged fabricated products
through large North American distributors.
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Products sold for custom
automotive and industrial applications represented 27% of 2005
fabricated products shipments. These products include custom
extruded, drawn and forged aluminum products for a variety of
applications. While we are capable of producing forged products
for most end-use applications, we concentrate our efforts on
meeting demand for forged products, other than wheels, in the
automotive industry.
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We have elected not to participate in certain end markets for
fabricated aluminum products, including beverage and food cans,
building and construction materials, and foil used for
packaging, which represented approximately 95% of the North
American flat-rolled products market and approximately 45% of
the North American extrusion market in 2005. We believe our
chosen end markets present better opportunities for sales growth
and premium pricing of differentiated products.
Aerospace and defense applications
We are a leading supplier of high quality sheet, plate, drawn
tube and bar products to the global aerospace and defense
industry. Our products for these end-use applications are heat
treat plate and sheet, as well as cold finish bar and seamless
drawn tube that are manufactured to demanding specifications.
The aerospace and defense markets consumption of
fabricated aluminum products is driven by overall levels of
industrial production, cyclical airframe build rates and defense
spending, as well as the potential availability of competing
materials such as composites. According to Airline
Monitors July 2006 forecast, the global build rate of
commercial aircraft over 50 seats is expected to rise at a
4.6% compound annual growth rate through 2025. Additionally,
demand growth is expected to increase for thick plate with
growth in monolithic construction of commercial and
other aircraft. In monolithic construction, aluminum plate is
heavily machined to form the desired part from a single
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piece of metal (as opposed to creating parts using aluminum
sheet, extrusions or forgings that are affixed to one another
using rivets, bolts or welds). In addition to commercial
aviation demand, military applications for heat treat plate and
sheet include aircraft frames and skins and armor plating to
protect ground vehicles from explosive devices.
General engineering applications
General engineering products consist primarily of standard
catalog items sold to large metal distributors. These products
have a wide range of uses, many of which involve further
fabrication for numerous transportation and industrial end-use
applications where machining of plate, rod and bar is intensive.
Demand growth and cyclicality for general engineering products
tend to mirror broad economic patterns and industrial activity
in North America. Demand is also impacted by the destocking and
restocking of inventory in the full supply chain.
Custom automotive and industrial applications
We manufacture custom extruded/drawn and forged aluminum
products for many automotive and industrial end uses, including
consumer durables, electrical, machinery and equipment,
automobile, light truck, heavy truck and truck trailer
applications. Examples of the wide variety of custom products
that we supply to the automotive industry are extruded products
for anti-lock braking systems, drawn tube for drive shafts and
forgings for suspension control arms and drive train yokes.
Demand growth and cyclicality tend to mirror broad economic
patterns and industrial activity in North America, with specific
individual market segments such as automotive, heavy truck and
truck trailer applications tracking their respective build rates.
RISK FACTORS
Investing in our common stock involves risk. Before you invest
in our common stock, you should carefully consider the matters
discussed under the headings Risk factors and
Special note regarding forward-looking statements
and all other information contained in this prospectus.
OUR CORPORATE INFORMATION
We were incorporated in February 1987 under Delaware law. Our
principal executive offices are located at 27422 Portola
Parkway, Suite 350, Foothill Ranch, California 92610-2831,
and our telephone number at this address is (949) 614-1740.
Our website is www.kaiseraluminum.com. Information on, or
accessible through, our website is not a part of, and is not
incorporated into, this prospectus.
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The offering
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Common stock offered by the selling stockholders |
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5,461,870 shares |
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Common stock outstanding before and after the offering |
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20,525,660 shares |
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Over-allotment option |
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The Union VEBA Trust has granted the underwriters a
30-day option to
purchase up to 819,280 additional shares of our common
stock to cover over-allotments. |
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Nasdaq Global Market symbol |
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KALU |
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Use of proceeds |
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We will receive no proceeds from the sale of common stock by the
selling stockholders. |
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Transfer restrictions |
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Our common stock is subject to certain transfer restrictions
that potentially prohibit or void transfers by any person or
group that is, or as a result of such transfer would become, a
5% stockholder. See Description of capital
stock Restrictions on Transfer of Common Stock. |
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Risk factors |
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You should carefully read and consider the information set forth
under Risk factors, together with all of the other
information set forth in this prospectus, before deciding to
invest in shares of our common stock. |
Unless we indicate otherwise, the number of shares of common
stock shown to be outstanding before and after the offering is
based on shares outstanding on December 31, 2006 and
excludes 1,696,562 shares of common stock reserved and
available for issuance under our equity incentive plan.
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Summary consolidated financial and operating data
The following tables set forth our summary consolidated
financial and operating data as of the dates and for the periods
indicated below. The summary consolidated statement of income
data for the three years ended December 31, 2003, 2004 and
2005 are derived from our audited consolidated financial
statements included elsewhere in this prospectus.
As a result of the effectiveness of our plan of reorganization
on July 6, 2006, we adopted fresh start reporting in
accordance with American Institute of Certified Professional
Accountants Statement of
Position 90-7,
Financial Reporting by Entities in Reorganization Under the
Bankruptcy Code, or
SOP 90-7, as of
July 1, 2006. Because
SOP 90-7 requires
us to restate our stockholders equity to our
reorganization value and to allocate such value to our assets
and liabilities based on their fair values, our financial
condition and results of operations after June 30, 2006
will not be comparable in some material respects to the
financial condition or results of operations reflected in our
historical financial statements at dates or for periods prior to
July 1, 2006. This makes it difficult to assess our future
prospects based on historical performance.
Our emergence from chapter 11 bankruptcy and the adoption
of fresh start reporting resulted in a new reporting entity for
accounting purposes. Although we emerged from chapter 11
bankruptcy on July 6, 2006, we adopted fresh start
reporting under the provisions of
SOP 90-7 effective
as of the beginning of business on July 1, 2006. As such,
it was assumed that our emergence from chapter 11
bankruptcy was completed instantaneously at the beginning of
business on July 1, 2006 such that all operating activities
during the three months ended September 30, 2006 are
reported as applying to the new reporting entity. We believe
that this is a reasonable presentation as there were no material
transactions between July 1, 2006 and July 6, 2006
other than plan of reorganization-related transactions.
The accompanying financial statements include our financial
statements for both before and after our emergence from
chapter 11 bankruptcy. Financial information related to the
newly emerged entity is generally referred to throughout this
prospectus as successor information and financial
information related to the pre-emergence entity is generally
referred to as predecessor information. The
financial information of the successor entity is not comparable
to that of the predecessor given the effects of the plan of
reorganization, the adoption of fresh start reporting and other
factors.
The summary consolidated financial data as of and for the nine
months ended September 30, 2005 and 2006 are derived from
our unaudited consolidated financial statements included
elsewhere in this prospectus. We have prepared our unaudited
consolidated financial statements on the same basis as our
audited consolidated financial statements (except as set forth
in Note 2 of our interim consolidated financial statements)
and have included all adjustments, consisting of normal and
recurring adjustments, that we consider necessary for a fair
presentation of our financial position and operating results for
the unaudited period. The summary consolidated financial and
operating data as of and for the nine months ended
September 30, 2006 are not necessarily indicative of the
results that may be obtained for a full year.
With respect to the nine months ended September 30, 2006,
the successors operating data for the period from
July 1, 2006 through September 30, 2006 have been
combined with the predecessors operating data for the
period from January 1, 2006 to July 1, 2006 and are
compared to the predecessors operating data for the nine
months ended September 30, 2005.
The information presented in the following tables should be read
in conjunction with Capitalization, Selected
historical consolidated financial data,
Managements discussion and analysis of financial
condition and results of operations and the consolidated
financial statements and the notes thereto included elsewhere in
this prospectus.
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Predecessor | |
|
nine months | |
|
from | |
|
|
July 1, 2006 | |
|
|
year ended December 31, | |
|
ended | |
|
January 1, | |
|
|
through | |
|
|
| |
|
September 30, | |
|
2006 to | |
|
|
September 30, | |
Statements of income data: |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
July 1, 2006 | |
|
|
2006 | |
| |
(dollars in millions) |
|
|
|
(unaudited) | |
|
|
|
|
|
|
(restated)(1) | |
|
(unaudited) | |
|
|
(unaudited) | |
Net sales
|
|
$ |
710.2 |
|
|
$ |
942.4 |
|
|
$ |
1,089.7 |
|
|
$ |
815.9 |
|
|
$ |
689.8 |
|
|
|
$ |
331.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of products sold
|
|
|
681.2 |
|
|
|
852.2 |
|
|
|
951.1 |
|
|
|
710.9 |
|
|
|
596.4 |
|
|
|
|
291.8 |
|
|
Depreciation and amortization
|
|
|
25.7 |
|
|
|
22.3 |
|
|
|
19.9 |
|
|
|
15.0 |
|
|
|
9.8 |
|
|
|
|
2.8 |
|
|
Selling, administrative, research and development, and general
|
|
|
92.5 |
|
|
|
92.3 |
|
|
|
50.9 |
|
|
|
38.0 |
|
|
|
30.3 |
|
|
|
|
18.0 |
|
|
Other operating charges (credits), net
(2)
|
|
|
141.6 |
|
|
|
793.2 |
|
|
|
8.0 |
|
|
|
6.5 |
|
|
|
0.9 |
|
|
|
|
(2.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses
|
|
|
941.0 |
|
|
|
1,760.0 |
|
|
|
1,029.9 |
|
|
|
770.4 |
|
|
|
637.4 |
|
|
|
|
309.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Operating income (loss)
|
|
|
(230.8 |
) |
|
|
(817.6 |
) |
|
|
59.8 |
|
|
|
45.5 |
|
|
|
52.4 |
|
|
|
|
21.7 |
|
Other income (expense):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Interest
expense(3)
|
|
|
(9.1 |
) |
|
|
(9.5 |
) |
|
|
(5.2 |
) |
|
|
(4.2 |
) |
|
|
(0.8 |
) |
|
|
|
|
|
|
Reorganization
items(4)
|
|
|
(27.0 |
) |
|
|
(39.0 |
) |
|
|
(1,162.1 |
) |
|
|
(25.3 |
) |
|
|
3,093.1 |
|
|
|
|
|
|
|
Other, net
|
|
|
(5.2 |
) |
|
|
4.2 |
|
|
|
(2.4 |
) |
|
|
(1.5 |
) |
|
|
1.2 |
|
|
|
|
0.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before income taxes and discontinued operations
|
|
|
(272.1 |
) |
|
|
(861.9 |
) |
|
|
(1,109.9 |
) |
|
|
14.5 |
|
|
|
3,145.9 |
|
|
|
|
22.6 |
|
Provision for income taxes
|
|
|
(1.5 |
) |
|
|
(6.2 |
) |
|
|
(2.8 |
) |
|
|
(6.0 |
) |
|
|
(6.2 |
) |
|
|
|
(8.3 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations
|
|
|
(273.6 |
) |
|
|
(868.1 |
) |
|
|
(1,112.7 |
) |
|
|
8.5 |
|
|
|
3,139.7 |
|
|
|
|
14.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Discontinued operations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations, net of income taxes,
including minority interests
|
|
|
(514.7 |
) |
|
|
(5.3 |
) |
|
|
(2.5 |
) |
|
|
21.3 |
|
|
|
4.3 |
|
|
|
|
|
|
|
Gain from sale of commodity interests
|
|
|
|
|
|
|
126.6 |
|
|
|
366.2 |
|
|
|
365.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations
(5)
|
|
|
(514.7 |
) |
|
|
121.3 |
|
|
|
363.7 |
|
|
|
386.9 |
|
|
|
4.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cumulative effect on years prior to 2005 of adopting accounting
for conditional asset retirement obligations
|
|
|
|
|
|
|
|
|
|
|
(4.7 |
) |
|
|
(4.7 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
(788.3 |
) |
|
$ |
(746.8 |
) |
|
$ |
(753.7 |
) |
|
$ |
390.7 |
|
|
$ |
3,144.0 |
|
|
|
$ |
14.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nine months | |
|
|
|
|
ended | |
|
|
Year ended December 31, | |
|
September 30, | |
|
|
| |
|
| |
Operating data (unaudited): |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
2006 | |
| |
Shipments (millions of pounds):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated products
|
|
|
372.3 |
|
|
|
458.6 |
|
|
|
481.9 |
|
|
|
365.2 |
|
|
|
399.7 |
|
|
Primary aluminum
|
|
|
158.7 |
|
|
|
156.6 |
|
|
|
155.6 |
|
|
|
115.7 |
|
|
|
117.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
|
531.0 |
|
|
|
615.2 |
|
|
|
637.5 |
|
|
|
480.9 |
|
|
|
516.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Average realized third-party sales price (per pound):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated
products(6)
|
|
$ |
1.61 |
|
|
$ |
1.76 |
|
|
$ |
1.95 |
|
|
$ |
1.94 |
|
|
$ |
2.18 |
|
|
Primary
aluminum(7)
|
|
$ |
0.71 |
|
|
$ |
0.85 |
|
|
$ |
0.95 |
|
|
$ |
0.93 |
|
|
$ |
1.27 |
|
Capital expenditures, net of accounts payable (excluding
discontinued operations) (in millions)
|
|
$ |
8.9 |
|
|
$ |
7.6 |
|
|
$ |
31.0 |
|
|
$ |
20.4 |
|
|
$ |
39.7 |
|
(footnotes on following page)
8
|
|
|
|
|
|
|
As of | |
|
|
September 30, | |
Balance sheet data: |
|
2006 | |
| |
(dollars in millions) |
|
(unaudited) | |
Cash and cash equivalents
|
|
$ |
52.7 |
|
Working
capital(8)
|
|
|
212.1 |
|
Total assets
|
|
|
621.1 |
|
Long-term debt
|
|
|
50.0 |
|
Stockholders equity (deficit)
|
|
|
345.9 |
|
|
|
(1) |
We restated our operating results for the nine months ended
September 30, 2005. See Note 15 to our interim
consolidated financial statements for information regarding the
restatement. |
|
(2) |
Other operating charges (credits), net in 2003 and 2004
include certain significant charges associated with the
termination of certain pension and post-retirement medical
plans, a settlement in respect of a past labor matter and other
items. These items are detailed in Note 6 to our audited
consolidated financial statements and Note 10 to our
interim consolidated financial statements. |
|
(3) |
Excludes unrecorded contractual interest expense of
$95.0 million in each of 2003, 2004 and 2005,
$71.2 million for the nine months ended September 30,
2005 and $47.4 million for the period from January 1,
2006 to July 1, 2006. |
|
(4) |
Reorganization items for 2005 include an approximate
$1.1 billion charge as a result of the value of an
intercompany note treated as being for the benefit of certain
creditors. See Note 1 to our audited consolidated financial
statements. Reorganization items for the period from
January 1, 2006 to July 1, 2006 include a gain of
approximately $3.1 billion in connection with the
implementation of our plan of reorganization and fresh start
reporting. See Note 13 to our interim consolidated
financial statements. |
|
(5) |
Income (loss) from discontinued operations includes a
substantial impairment charge in 2003 and gains in 2004 and 2005
in connection with the sale of certain of our commodity-related
interests. See Note 3 to our audited consolidated financial
statements. |
|
(6) |
Average realized prices for our fabricated products business
unit are subject to fluctuations due to changes in product mix
as well as underlying primary aluminum prices and are not
necessarily indicative of changes in underlying
profitability. |
|
(7) |
Average realized prices for our primary aluminum business
unit exclude hedging revenues. |
|
(8) |
Working capital represents total current assets, including
cash, minus total current liabilities. |
9
Risk factors
An investment in our common stock involves various risks.
Before making an investment in our common stock, you should
carefully consider the following risks, as well as the other
information contained in this prospectus, including our
consolidated financial statements and the notes thereto and
Managements discussion and analysis of financial
condition and results of operations. The risks described
below are those which we believe are the material risks we face.
The occurrence of any of the events discussed below could
significantly and adversely affect our business, prospects,
financial condition, results of operations and cash flows. As a
result, the trading price of our common stock could decline and
you may lose a part or all of your investment.
RISKS RELATING TO OUR BUSINESS AND OUR INDUSTRY
We recently emerged from chapter 11 bankruptcy, have
sustained losses in the past and may not be able to maintain
profitability.
Because we recently emerged from chapter 11 bankruptcy and
have in the past sustained losses, we cannot assure you that we
will be able to maintain profitability in the future. We sought
protection under chapter 11 of the Bankruptcy Code in
February 2002. We emerged from bankruptcy as a reorganized
entity on July 6, 2006. Prior to and during this
reorganization, we incurred substantial net losses, including
net losses of $788.3 million, $746.8 million and
$753.7 million in the fiscal years ended December 31,
2003, 2004 and 2005, respectively. If we cannot maintain
profitability, the value of your investment in Kaiser may
decline.
You may not be able to compare our historical financial
information to our future financial information, which will make
it more difficult to evaluate an investment in our company.
As a result of the effectiveness of our plan of reorganization
on July 6, 2006, we are operating our business under a new
capital structure. In addition, we adopted fresh start reporting
in accordance with
SOP 90-7 as of
July 1, 2006. Because
SOP 90-7 requires
us to account for our assets and liabilities at their fair
values as of the effectiveness of our plan of reorganization,
our financial condition and results of operations from and after
July 1, 2006 will not be comparable in some material
respects to the financial condition or results of operations
reflected in our historical financial statements at dates or for
periods prior to July 1, 2006. This may make it difficult
to assess our future prospects based on historical performance.
We operate in a highly competitive industry which could
adversely affect our profitability.
The fabricated products segment of the aluminum industry is
highly competitive. Competition in the sale of fabricated
aluminum products is based upon quality, availability, price and
service, including delivery performance. Many of our competitors
are substantially larger than we are and have greater financial
resources than we do, and may have other strategic advantages,
including more efficient technologies or lower raw material and
energy costs. Our facilities are primarily located in North
America. To the extent that our competitors have production
facilities located outside North America, they may be able to
produce similar products at a lower cost. We may not be able to
adequately reduce costs to compete with these products.
Increased competition could cause a reduction in our shipment
volumes and profitability or increase our expenditures, any one
of which could have a material adverse effect on our financial
position, results of operations and cash flows.
We depend on a core group of significant customers.
In 2005 and for the nine months ended September 30, 2006,
our largest fabricated products customer, Reliance
Steel & Aluminum, accounted for approximately 11% and
19%, respectively, of our fabricated products net sales, and our
five largest customers accounted for approximately 33% and 42%,
respectively, of our fabricated products net sales. The increase
in the percentage of our net sales
10
Risk factors
to our largest fabricated products customer is the result of
Reliance acquiring one of our other top five customers in the
second quarter of 2006. Sales to Reliance and the other customer
(on a combined basis) accounted for approximately 19% of our net
sales in 2005 and for the nine months ended September 30,
2006. If our existing relationships with significant customers
materially deteriorate or are terminated and we are not
successful in replacing lost business, our financial position,
results of operations and cash flows could be materially and
adversely affected. The loss of Reliance as a customer could
have a material adverse effect on our financial position,
results of operations and cash flows. In addition, a significant
downturn in the business or financial condition of any of our
significant customers could materially and adversely affect our
financial position, results of operations and cash flows.
Some of our current and former international customers,
particularly automobile manufacturers in Europe and Japan, were
reluctant to do business with us while we underwent
chapter 11 bankruptcy reorganization, presumably because of
their unfamiliarity with U.S. bankruptcy laws and the
uncertainty about the strength of our business. Although we
believe our emergence from chapter 11 bankruptcy should
mitigate such reluctance, we cannot assure you that this will be
the case.
Our industry is very sensitive to foreign economic,
regulatory and political factors that may adversely affect our
business.
We import primary aluminum from, and manufacture fabricated
products used in, foreign countries. We also own 49% of
Anglesey, which owns and operates an aluminum smelter in the
United Kingdom. We purchase alumina to supply to Anglesey and we
purchase aluminum from Anglesey for sale to a third party in the
United Kingdom. Factors in the politically and economically
diverse countries in which we operate or have customers or
suppliers, including inflation, fluctuations in currency and
interest rates, competitive factors, civil unrest and labor
problems, could affect our financial position, results of
operations and cash flows. Our financial position, results of
operations and cash flows could also be adversely affected by:
|
|
|
acts of war or terrorism or the
threat of war or terrorism;
|
|
|
government regulation in the
countries in which we operate, service customers or purchase raw
materials;
|
|
|
the implementation of controls
on imports, exports or prices;
|
|
|
the adoption of new forms of
taxation;
|
|
|
the imposition of currency
restrictions;
|
|
|
the nationalization or
appropriation of rights or other assets; and
|
|
|
trade disputes involving
countries in which we operate, service customers or purchase raw
materials.
|
The aerospace industry is cyclical and downturns in the
aerospace industry, including downturns resulting from acts of
terrorism, could adversely affect our revenues and
profitability.
We derive a significant portion of our revenue from products
sold to the aerospace industry, which is highly cyclical and
tends to decline in response to overall declines in industrial
production. As a result, our business is affected by overall
levels of industrial production and fluctuations in the
aerospace industry. The commercial aerospace industry is
historically driven by the demand from commercial airlines for
new aircraft. Demand for commercial aircraft is influenced by
airline industry profitability, trends in airline passenger
traffic, by the state of the U.S. and world economies and
numerous other factors, including the effects of terrorism. The
military aerospace cycle is highly dependent on U.S. and foreign
government funding; however, it is also driven by the effects of
terrorism, a changing global political environment,
U.S. foreign policy, regulatory changes, the retirement of
older aircraft and
11
Risk factors
technological improvements to new aircraft engines that increase
reliability. The timing, duration and severity of cyclical
upturns and downturns cannot be predicted with certainty. A
future downturn or reduction in demand could have a material
adverse effect on our financial position, results of operations
and cash flows.
In addition, because we and other suppliers are expanding
production capacity to alleviate the current supply shortage for
heat treat aluminum plate, heat treat plate prices may
eventually begin to decrease as production capacity increases.
Although we have implemented cost reduction and sales growth
initiatives to minimize the impact on our results of operations
as heat treat plate prices return to more typical historical
levels, these initiatives may not be adequate and our financial
position, results of operations and cash flows may be adversely
affected.
A number of major airlines have also recently undergone or are
undergoing chapter 11 bankruptcy and continue to experience
financial strain from high fuel prices. Continued financial
instability in the industry may lead to reduced demand for new
aircraft that utilize our products, which could adversely affect
our financial position, results of operations and cash flows.
The aerospace industry suffered significantly in the wake of the
events of September 11, 2001, resulting in a sharp decrease
globally in new commercial aircraft deliveries and order
cancellations or deferrals by the major airlines. This decrease
reduced the demand for our Aero/ HS products. While there has
been a recovery since 2001, the threat of terrorism and fears of
future terrorist acts could negatively affect the aerospace
industry and our financial position, results of operations and
cash flows.
Our customers may reduce their demand for aluminum products
in favor of alternative materials.
Our fabricated aluminum products compete with products made from
other materials, such as steel and composites, for various
applications. For instance, the commercial aerospace industry
has used and continues to evaluate the further use of
alternative materials to aluminum, such as composites, in order
to reduce the weight and increase the fuel efficiency of
aircraft. The willingness of customers to accept substitutions
for aluminum or the ability of large customers to exert leverage
in the marketplace to reduce the pricing for fabricated aluminum
products could adversely affect the demand for our products,
particularly our Aero/ HS products, and thus adversely affect
our financial position, results of operations and cash flows.
Downturns in the automotive industry could adversely affect
our net sales and profitability.
The demand for many of our general engineering and custom
products is dependent on the production of automobiles, light
trucks and heavy duty vehicles in North America. The automotive
industry is highly cyclical, as new vehicle demand is dependent
on consumer spending and is tied closely to the overall strength
of the North American economy. The North American automotive
industry is facing costly inventory corrections which could
adversely affect our net sales and profitability. Recent
production cuts announced by General Motors Corporation, Ford
Motor Company and DaimlerChrysler AG, as well as cutbacks in
heavy duty truck production, may adversely affect the demand for
our products. If the financial condition of these auto
manufacturers continues to be unsteady or if any of the three
seek restructuring or relief through bankruptcy proceedings, the
demand for our products may decline, adversely affecting our net
sales and profitability. Any decline in the demand for new
automobiles, particularly in the United States, could have a
material adverse effect on our financial position, results of
operations and cash flows. Seasonality experienced by the
automotive industry in the third and fourth quarters of the
calendar year also affects our financial position, results of
operations and cash flows.
12
Risk factors
Because our products are often components of our
customers products, reductions in demand for our products
may be more severe than, and may occur prior to reductions in
demand for, our customers products.
Our products are often components of the end-products of our
customers. Customers purchasing our fabricated aluminum
products, such as those in the cyclical automotive and aerospace
industries, generally require significant lead time in the
production of their own products. Therefore, demand for our
products may increase prior to demand for our customers
products. Conversely, demand for our products may decrease as
our customers anticipate a downturn in their respective
businesses. As demand for our customers products begins to
soften, our customers typically reduce or eliminate their demand
for our products and meet the reduced demand for their products
using their own inventory without replenishing that inventory,
which results in a reduction in demand for our products that is
greater than the reduction in demand for their products. This
amplified reduction in demand for our products in the event of a
downswing in our customers respective businesses may
adversely affect our financial position, results of operations
and cash flows.
Our business is subject to unplanned business interruptions
which may adversely affect our performance.
The production of fabricated aluminum products is subject to
unplanned events such as explosions, fires, inclement weather,
natural disasters, accidents, transportation interruptions and
supply interruptions. Operational interruptions at one or more
of our production facilities, particularly interruptions at our
Trentwood facility in Spokane, Washington where our production
of plate and sheet is concentrated, could cause substantial
losses in our production capacity. Furthermore, because
customers may be dependent on planned deliveries from us,
customers that have to reschedule their own production due to
our delivery delays may be able to pursue financial claims
against us, and we may incur costs to correct such problems in
addition to any liability resulting from such claims. Such
interruptions may also harm our reputation among actual and
potential customers, potentially resulting in a loss of
business. To the extent these losses are not covered by
insurance, our financial position, results of operations and
cash flows may be adversely affected by such events.
Covenants and events of default in our debt instruments could
limit our ability to undertake certain types of transactions and
adversely affect our liquidity.
Our revolving credit facility and term loan facility contain
negative and financial covenants and events of default that may
limit our financial flexibility and ability to undertake certain
types of transactions. For instance, we are subject to negative
covenants that restrict our activities, including restrictions
on creating liens, engaging in mergers, consolidations and sales
of assets, incurring additional indebtedness, providing
guaranties, engaging in different businesses, making loans and
investments, making certain dividends, debt and other restricted
payments, making certain prepayments of indebtedness, engaging
in certain transactions with affiliates and entering into
certain restrictive agreements. If we fail to satisfy the
covenants set forth in our revolving credit facility and term
loan facility or another event of default occurs under these
facilities, the maturity of the loans could be accelerated or,
in the case of the revolving credit facility, we could be
prohibited from borrowing for our working capital needs. If the
loans are accelerated and we do not have sufficient cash on hand
to pay all amounts due, we could be required to sell assets, to
refinance all or a portion of our indebtedness or to obtain
additional financing. Refinancing may not be possible and
additional financing may not be available on commercially
acceptable terms, or at all. If we cannot borrow under the
revolving credit facility to meet our working capital needs, we
would need to seek additional financing, if available, or
curtail our operations.
13
Risk factors
We depend on our subsidiaries for cash to meet our
obligations and pay any dividends.
We are a holding company. Our subsidiaries conduct all of our
operations and own substantially all of our assets.
Consequently, our cash flow and our ability to meet our
obligations or pay dividends to our stockholders depend upon the
cash flow of our subsidiaries and the payment of funds by our
subsidiaries to us in the form of dividends, tax sharing
payments or otherwise. Our subsidiaries ability to make
any payment will depend on their earnings, the terms of their
indebtedness (including the revolving credit facility and term
loan facility), tax considerations and legal restrictions.
We may not be able to successfully implement our productivity
and cost reduction initiatives.
We have undertaken and may continue to undertake productivity
and cost reduction initiatives to improve performance, including
deployment of company-wide business improvement methodologies,
such as the Kaiser Production System, which involves the
integrated utilization of application and advanced process
engineering and business improvement methodologies such as lean
enterprise, total productive maintenance and six sigma. We
cannot assure you that these initiatives will be completed or
beneficial to us or that any estimated cost saving from such
activities will be realized. Even if we are able to generate new
efficiencies successfully in the short to medium term, we may
not be able to continue to reduce cost and increase productivity
over the long term.
Our profitability could be adversely affected by increases in
the cost of raw materials.
The price of primary aluminum has historically been subject to
significant cyclical price fluctuations, and the timing of
changes in the market price of aluminum is largely
unpredictable. Although our pricing of fabricated aluminum
products is generally intended to pass the risk of price
fluctuations on to our customers, we may not be able to pass on
the entire cost of such increases to our customers or offset
fully the effects of higher costs for other raw materials, which
may cause our profitability to decline. There will also be a
potential time lag between increases in prices for raw materials
under our purchase contracts and the point when we can implement
a corresponding increase in price under our sales contracts with
our customers. As a result, we may be exposed to fluctuations in
raw materials prices, including aluminum, since, during the time
lag, we may have to bear the additional cost of the price
increase under our purchase contracts. If these events were to
occur, they could have a material adverse effect on our
financial position, results of operations and cash flows.
Furthermore, we are party to arrangements based on fixed prices
that include the primary aluminum price component, so that we
bear the entire risk of rising aluminum prices, which may cause
our profitability to decline. In addition, an increase in raw
materials prices may cause some of our customers to substitute
other materials for our products, adversely affecting our
results of operations due to both a decrease in the sales of
fabricated aluminum products and a decrease in demand for the
primary aluminum produced at Anglesey.
We are responsible for selling alumina to Anglesey in proportion
to our ownership percentage at a predetermined price. Such
alumina currently is purchased under contracts that extend
through 2007 at prices that are tied to primary aluminum prices.
We will need to secure a new alumina contract for the period
after 2007. We cannot assure you that we will be able to secure
a source of alumina at comparable prices. If we are unable to do
so, our financial position, results of operations and cash flows
associated with our primary aluminum business segment may be
adversely affected.
The price volatility of energy costs may adversely affect our
profitability.
Our income and cash flows depend on the margin above fixed and
variable expenses (including energy costs) at which we are able
to sell our fabricated aluminum products. The volatility in
costs of fuel, principally natural gas, and other utility
services, principally electricity, used by our production
facilities affect operating costs. Fuel and utility prices have
been, and will continue to be, affected by factors outside our
control, such as supply and demand for fuel and utility services
in both local and
14
Risk factors
regional markets. The daily closing price of the front-month
futures contract for natural gas per million British thermal
units as reported on NYMEX ranged between $4.43 and $9.58 in
2003, between $4.57 and $8.75 in 2004, between $5.79 and $15.38
in 2005 and between $4.20 and $10.63 in the nine month period
ended September 30, 2006. Typically, electricity prices
fluctuate with natural gas prices which increases our exposure
to energy costs. Future increases in fuel and utility prices may
have an adverse effect on our financial position, results of
operations and cash flows.
Our hedging programs may limit the income and cash flows we
would otherwise expect to receive if our hedging program were
not in place.
From time to time in the ordinary course of business, we may
enter into hedging transactions to limit our exposure to price
risks relating to primary aluminum prices, energy prices and
foreign currency. To the extent that these hedging transactions
fix prices or exchange rates and the prices for primary aluminum
exceed the fixed or ceiling prices established by these hedging
transactions or energy costs or foreign exchange rates are below
the fixed prices, our income and cash flows will be lower than
they otherwise would have been.
The expiration of the power agreement for Anglesey may
adversely affect our cash flows and affect our hedging
programs.
The agreement under which Anglesey receives power expires in
September 2009, and the nuclear facility which supplies such
power is scheduled to cease operations shortly thereafter. As of
the date of this prospectus, Anglesey has not identified a
source from which to obtain sufficient power to sustain its
operations on reasonably acceptable terms thereafter, and we
cannot assure you that Anglesey will be able to do so. If, as a
result, Angleseys aluminum production is curtailed or its
costs are increased, our cash flows may be adversely affected.
In addition, any decrease in Angleseys production would
reduce or eliminate the natural hedge against rising
primary aluminum prices created by our participation in the
primary aluminum market and, accordingly, we may deem it
appropriate to increase our hedging activity to limit exposure
to such price risks, potentially adversely affecting our
financial position, results of operations and cash flows.
If Anglesey cannot obtain sufficient power, Angleseys
operations will likely be shut down. Given the potential for
future shutdown and related costs, dividends from Anglesey have
been suspended while Anglesey studies future cash requirements.
The shutdown process may involve significant costs to Anglesey
which would decrease or eliminate its ability to pay dividends.
The process of shutting down operations may involve transition
complications which may prevent Anglesey from operating at full
capacity until the expiration of the power contract. As a
result, our financial position, results of operations and cash
flows may be negatively affected even before the September 2009
expiration of the power contract.
Our ability to keep key management and other personnel in
place and our ability to attract management and other personnel
may affect our performance.
We depend on our senior executive officers and other key
personnel to run our business. The loss of any of these officers
or other key personnel could materially and adversely affect our
operations. Competition for qualified employees among companies
that rely heavily on engineering and technology is intense, and
the loss of qualified employees or an inability to attract,
retain and motivate additional highly skilled employees required
for the operation and expansion of our business could hinder our
ability to improve manufacturing operations, conduct research
activities successfully or develop marketable products.
15
Risk factors
Our production costs may increase and we may not sustain our
sales and earnings if we fail to maintain satisfactory labor
relations.
A significant number of our employees are represented by labor
unions under labor contracts with varying durations and
expiration dates. We may not be able to renegotiate our labor
contracts when they expire on satisfactory terms or at all. A
failure to do so may increase our costs or cause us to limit or
halt operations before a new agreement is reached. In addition,
our existing labor agreements may not prevent a strike or work
stoppage, and any work stoppage could have a material adverse
effect on our financial position, results of operations and cash
flows.
Our business is regulated by a wide variety of health and
safety laws and regulations and compliance may be costly and may
adversely affect our results of operations.
Our operations are regulated by a wide variety of health and
safety laws and regulations. Compliance with these laws and
regulations may be costly and could have a material adverse
effect on our results of operations. In addition, these laws and
regulations are subject to change at any time, and we can give
you no assurance as to the effect that any such changes would
have on our operations or the amount that we would have to spend
to comply with such laws and regulations as so changed.
Environmental compliance, clean up and damage claims may
decrease our cash flow and adversely affect our results of
operations.
We are subject to numerous environmental laws and regulations
with respect to, among other things: air and water emissions and
discharges; the generation, storage, treatment, transportation
and disposal of solid and hazardous waste; and the release of
hazardous or toxic substances, pollutants and contaminants into
the environment. Compliance with these environmental laws is and
will continue to be costly.
Our operations, including our operations conducted prior to our
emergence from chapter 11 bankruptcy, have subjected, and
may in the future subject, us to fines or penalties for alleged
breaches of environmental laws and to obligations to perform
investigations or clean up of the environment. We may also be
subject to claims from governmental authorities or third parties
related to alleged injuries to the environment, human health or
natural resources, including claims with respect to waste
disposal sites, the clean up of sites currently or formerly used
by us or exposure of individuals to hazardous materials. Any
investigation, clean-up or other remediation costs, fines or
penalties, or costs to resolve third-party claims may be costly
and could have a material adverse effect on our financial
position, results of operations and cash flows.
We have accrued, and will accrue, for costs relating to the
above matters that are reasonably expected to be incurred based
on available information. However, it is possible that actual
costs may differ, perhaps significantly, from the amounts
expected or accrued, and such differences could have a material
adverse effect on our financial position, results of operations
and cash flows. In addition, new laws or regulations or changes
to existing laws and regulations may occur, and we cannot assure
you as to the amount that we would have to spend to comply with
such new or amended laws and regulations or the effects that
they would have on our financial position, results of operations
and cash flows.
Other legal proceedings or investigations or changes in the
laws and regulations to which we are subject may adversely
affect our results of operations.
In addition to the environmental matters described above, we may
from time to time be involved in, or be the subject of,
disputes, proceedings and investigations with respect to a
variety of matters, including matters related to health and
safety, personal injury, employees, taxes and contracts, as well
as other disputes and proceedings that arise in the ordinary
course of business. It could be costly to defend against these
claims or any investigations involving them, whether meritorious
or not, and legal
16
Risk factors
proceedings and investigations could divert managements
attention as well as operational resources, negatively affecting
our financial position, results of operations and cash flows. It
could also be costly to make payments on account of any such
claims.
Additionally, as with the environmental laws and regulations to
which we are subject, the other laws and regulations which
govern our business are subject to change at any time, and we
cannot assure you as to the amount that we would have to spend
to comply with such laws and regulations as so changed or
otherwise as to the effect that any such changes would have on
our operations.
Product liability claims against us could result in
significant costs or negatively affect our reputation and could
adversely affect our results of operations.
We are sometimes exposed to warranty and product liability
claims. We cannot assure you that we will not experience
material product liability losses arising from such claims in
the future. We generally maintain insurance against many product
liability risks but we cannot assure you that our coverage will
be adequate for liabilities ultimately incurred. In addition, we
cannot assure you that insurance will continue to be available
to us on terms acceptable to us. A successful claim that exceeds
our available insurance coverage could have a material adverse
effect on our financial position, results of operations and cash
flows.
Our Trentwood expansion project may not be completed as
scheduled.
We are currently in the process of a $105 million expansion
of production capacity and gauge capability at our Trentwood
facility. While the project is currently on schedule to be
completed in 2008, with substantially all costs being incurred
in 2006 and 2007, our ability to fully complete this project,
and the timing and costs of doing so, are subject to various
risks associated with all major construction projects, many of
which are beyond our control, including technical or mechanical
problems. If we are unable to fully complete this project or if
the actual costs for this project exceed our current
expectations, our financial position, results of operations and
cash flows would be adversely affected. In addition, we have
contracts currently in place expected to be fulfilled with
production from the expanded facility. If completion of the
expansion is significantly delayed or the expansion is not fully
completed, we may not be able to meet shipping deadlines on time
or at all, which would adversely affect our results of
operations, may lead to litigation and may damage our
relationships with these customers and our reputation generally.
We may not be able to successfully execute our strategy of
growth through acquisitions.
A component of our growth strategy is to acquire fabricated
products assets in order to complement our product portfolio.
Our ability to do so will be dependent upon a number of factors,
including our ability to identify acceptable acquisition
candidates, consummate acquisitions on favorable terms,
successfully integrate acquired assets, obtain financing to fund
acquisitions and support our growth and many other factors
beyond our control. Risks associated with acquisitions include
those relating to:
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diversion of managements
time and attention from our existing business;
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challenges in managing the
increased scope, geographic diversity and complexity of
operations;
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difficulties in integrating the
financial, technological and management standards, processes,
procedures and controls of the acquired business with those of
our existing operations;
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liability for known or unknown
environmental conditions or other contingent liabilities not
covered by indemnification or insurance;
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greater than anticipated
expenditures required for compliance with environmental or other
regulatory standards or for investments to improve operating
results;
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17
Risk factors
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difficulties in achieving
anticipated operational improvements;
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incurrence of additional
indebtedness to finance acquisitions or capital expenditures
relating to acquired assets; and
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issuance of additional equity,
which could result in further dilution of the ownership
interests of existing stockholders.
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We may not be successful in acquiring additional assets, and any
acquisitions that we do consummate may not produce the
anticipated benefits or may have adverse effects on our
financial position, results of operations and cash flows.
We have reported one material weakness relating to hedge
accounting in our internal control over financial reporting,
which resulted in the restatement of our financial statements,
and one significant deficiency.
During the first quarter of 2006 as part of the reporting and
closing process relating to the preparation of our
December 31, 2005 financial statements, we concluded that
our controls and procedures were not effective as of
December 31, 2005 because a material weakness in internal
control over financial reporting existed relating to our
accounting for derivative financial instruments. A material
weakness is a control deficiency, or combination of control
deficiencies, that results in more than a remote likelihood that
a material misstatement of our annual or interim financial
statements would not be prevented or detected. We concluded that
our procedures relating to hedging transactions were not
designed effectively and that our documentation did not comply
with certain accounting rules, thus requiring us to account for
our derivatives on a mark-to-market basis. While we are working
to modify our documentation and requalify certain derivative
transactions for treatment as hedges, and have engaged outside
experts to perform periodic reviews, we cannot assure you that
such improved controls will prevent any or all instances of
non-compliance. As a result of the material weakness, we
restated our financial statements for the quarters ended
March 31, 2005, June 30, 2005 and September 30,
2005 to reflect mark-to-market accounting. See
Managements discussion and analysis of financial
condition and results of operations Controls and
Procedures for more information. Until we requalify our
derivatives for hedge accounting treatment, we will not consider
this matter to be fully remediated.
We also concluded that the appropriate post-emergence accounting
treatment for VEBA payments made in 2005 required presentation
of VEBA payments as a reduction of pre-petition retiree medical
obligations rather than as a period expense, as we had concluded
in prior quarters. Our prior treatment of VEBA payments was
identified as a significant deficiency in our internal control
over financial reporting at December 31, 2005. We corrected
this deficiency during the preparation of our December 31,
2005 financial statements and, accordingly, such deficiency did
not exist at the end of subsequent periods.
Although we believe we have or will address these issues with
the remedial measures that we have implemented or plan to
implement, the measures we have taken to date and any future
measures may not be effective, and we may not be able to
implement and maintain effective internal control over financial
reporting in the future. In addition, other deficiencies in our
internal controls may be discovered in the future.
Any failure to implement new or improved controls, or
difficulties encountered in their implementation, could cause us
to fail to meet our reporting obligations or result in material
misstatements in our financial statements. Any such failure also
could affect the ability of our management to certify that our
internal controls are effective when it provides an assessment
of our internal control over financial reporting, and could
affect the results of our independent registered public
accounting firms attestation report regarding our
managements assessment. Inferior internal
18
Risk factors
controls and further related restatements could also cause
investors to lose confidence in our reported financial
information, which could have a negative effect on the trading
price of our stock.
We will be exposed to risks relating to evaluations of
controls required by Section 404 of the Sarbanes-Oxley Act
of 2002.
We are required to comply with Section 404 of the
Sarbanes-Oxley Act of 2002 by no later than December 31,
2007. We are in the process of evaluating our internal controls
systems to allow management to report on, and our independent
auditors to audit, our internal controls over financial
reporting. We will be performing the system and process
evaluation and testing (and any necessary remediation) required
to comply with the management certification and auditor
attestation requirements of Section 404. However, we cannot
be certain as to the timing of completion of our evaluation,
testing and remediation actions or the impact of the same on our
operations. Furthermore, upon completion of this process, we may
identify control deficiencies of varying degrees of severity
under applicable Securities and Exchange Commission, or SEC, and
Public Company Accounting Oversight Board rules and regulations
that remain unremediated. We will be required to report, among
other things, control deficiencies that constitute a
material weakness or changes in internal controls
that, or are reasonably likely to, materially affect internal
controls over financial reporting. A material
weakness is a control deficiency, or combination of
control deficiencies that results in more than a remote
likelihood that a material misstatement of the annual or interim
financial statements will not be prevented or detected. If we
fail to implement the requirements of Section 404 in a
timely manner, we might be subject to sanctions or investigation
by regulatory authorities such as the SEC or by Nasdaq.
Additionally, failure to comply with Section 404 or the
report by us of a material weakness may cause investors to lose
confidence in our financial statements and our stock price may
be adversely affected. If we fail to remedy any material
weakness, our financial statements may be inaccurate, we may not
have access to the capital markets, and our stock price may be
adversely affected.
We may not be able to adequately protect proprietary rights
to our technology.
Our success will depend in part upon our proprietary technology
and processes. Although we attempt to protect our intellectual
property through patents, trademarks, trade secrets, copyrights,
confidentiality and nondisclosure agreements and other measures,
these measures may not be adequate to protect such intellectual
property, particularly in foreign countries where the laws may
offer significantly less intellectual property protection than
is offered by the laws of the United States. In addition, any
attempts to enforce our intellectual property rights, even if
successful, could result in costly and prolonged litigation,
divert managements attention and adversely affect income
and cash flows. Failure to adequately protect our intellectual
property may adversely affect our results of operations as our
competitors would be able to utilize such property without
having had to incur the costs of developing it, thus potentially
reducing our relative profitability. Furthermore, we may be
subject to claims that our technology infringes the intellectual
property rights of another. Even if without merit, those claims
could result in costly and prolonged litigation, divert
managements attention and adversely affect our income and
cash flows. In addition, we may be required to enter into
licensing agreements in order to continue using technology that
is important to our business. However, we may be unable to
obtain license agreements on acceptable terms, which could
negatively affect our financial position, results of operations
and cash flows.
We may not be able to utilize all of our net operating loss
carry-forwards.
We have net operating loss carry-forwards and other significant
tax attributes that we believe could offset otherwise taxable
income. We previously disclosed our belief that these tax
attributes could together offset in the range of $555 to
$900 million of otherwise taxable income, and we currently
anticipate that, upon completion of our 2006 income tax return
analysis, the amount of our tax attributes as of
December 31, 2006 will likely be in the upper half of that
range. The amount of net operating loss carry-forwards available
in any year to offset our net taxable income will be reduced or
eliminated if we experience a
19
Risk factors
change of ownership as defined in the Internal
Revenue Code. We have entered into a stock transfer restriction
agreement with the Union VEBA Trust, our largest stockholder,
and our certificate of incorporation prohibits and voids certain
transfers of our common stock in order to reduce the risk that a
change of ownership will jeopardize our net operating loss
carry-forwards. See Description of capital
stockRestrictions on Transfer of Common Stock.
Because U.S. tax law limits the time during which
carry-forwards may be applied against future taxes, we may not
be able to take full advantage of the carry-forwards for federal
income tax purposes. In addition, the tax laws pertaining to net
operating loss carry-forwards may be changed from time to time
such that the net operating loss carry-forwards may be reduced
or eliminated. If the net operating loss carry-forwards become
unavailable to us or are fully utilized, our future income will
not be shielded from federal income taxation, thereby reducing
funds otherwise available for general corporate purposes.
RISKS RELATING TO THE SECURITIES MARKETS AND OWNERSHIP OF OUR
COMMON STOCK
Our current common stock has a limited trading history and a
small public float which may limit development of a market for
our common stock and increase the likelihood of significant
volatility in the market for our common stock.
In order to reduce the risk that any change in our ownership
would jeopardize the preservation of our federal income tax
attributes, including net operating loss carry-forwards, for
purposes of Sections 382 and 383 of the Internal Revenue
Code, upon emergence from chapter 11 bankruptcy, we entered
into a stock transfer restriction agreement with our largest
stockholder, the Union VEBA Trust, and amended and restated our
certificate of incorporation to include restrictions on
transfers involving 5% ownership. These transfer restrictions
could hinder development of an active market for our common
stock. In addition, the market price of our common stock may be
subject to significant fluctuations in response to numerous
factors, including variations in our annual or quarterly
financial results or those of our competitors, changes by
financial analysts in their estimates of our future earnings,
substantial amounts of our common stock being sold into the
public markets upon the expiration of share transfer
restrictions, which expire in July 2016, or upon the occurrence
of certain events relating to tax benefits available under
section 382 of the Internal Revenue Code, conditions in the
economy in general or in the fabricated aluminum products
industry in particular or unfavorable publicity.
Our net sales, operating results and profitability may vary
from period to period, which may lead to volatility in the
trading price of our stock.
Our financial and operating results may be significantly below
the expectations of public market analysts and investors and the
price of our common stock may decline due to the following
factors:
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volatility in the spot market
for primary aluminum and energy costs;
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our annual accruals for variable
payment obligations to the Union VEBA Trust and Salaried Retiree
VEBA Trust (see Note 7 to our interim consolidated
financial statements);
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non-cash charges including
last-in, first-out, or LIFO, inventory charges and impairments;
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global economic conditions;
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unanticipated interruptions of
our operations for any reason;
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variations in the maintenance
needs for our facilities;
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unanticipated changes in our
labor relations; and
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cyclical aspects impacting
demand for our products.
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Our annual variable payment obligation to the Union VEBA
Trust and Salaried Retiree VEBA Trust are linked with our
profitability, which means that not all of our earnings will be
available to our stockholders.
We are obligated to make annual payments to the Union VEBA Trust
and Salaried Retirees VEBA Trust calculated based on our
profitability and therefore not all of our earnings will be
available to
20
Risk factors
our stockholders. The aggregate amount of our annual payments to
these VEBAs is capped, however, at $20 million and is
subject to other limitations. As a result of these payment
obligations, our earnings and cash flows may be reduced.
A significant percentage of our stock is held by the Union
VEBA Trust which may exert significant influence over us.
The Union VEBA Trust currently owns 42.9% of our common stock.
After completion of this offering, the Union VEBA Trust will
hold 30.7% of our common stock, or 26.7% if the underwriters
exercise their over-allotment option in full. As a result, the
Union VEBA Trust will continue to have significant influence
over matters requiring stockholder approval, including the
composition of our board of directors. Further, to the extent
that the Union VEBA Trust and some or all of the other
substantial stockholders were to act in concert, they could
control any action taken by our stockholders. This concentration
of ownership could also facilitate or hinder proxy contests,
tender offers, open market purchase programs, mergers or other
purchases of our common stock that might otherwise give
stockholders the opportunity to realize a premium over the then
prevailing market price of our common stock or cause the market
price of our common stock to decline. We cannot assure you that
the interests of our major stockholders will not conflict with
our interests or the interests of our other investors.
The USW has director nomination rights through which it may
influence us, and USW interests may not align with our interests
or the interests of our other investors.
Pursuant to an agreement, the United Steel, Paper and Forestry,
Rubber, Manufacturing, Energy, Allied Industrial and Service
Workers International Union, AFL-CIO, CLC, or USW, has been
granted rights to nominate 40% of the candidates to be submitted
to our stockholders for election to our board of directors. As a
result, the directors nominated by the USW may have a
significant voice in the decisions of our board of directors.
We do not currently anticipate paying any dividends, and our
payment of dividends and stock repurchases are subject to
restriction.
We have not declared or paid any cash dividends on our common
stock since we filed chapter 11 bankruptcy in 2002. We
currently intend to retain all earnings for the operation and
expansion of our business and do not currently anticipate paying
any dividends on our common stock. The declaration and payment
of dividends, if any, in the future will be at the discretion of
the board of directors and will be dependent upon our results of
operations, financial condition, cash requirements, future
prospects and other factors. Accordingly, from time to time, the
board may declare dividends, though we can give you no assurance
in this regard. Moreover, our revolving credit facility and our
term loan facility restrict our ability to declare or pay
dividends or repurchase any shares of our common stock. In
addition, significant repurchases of our shares of common stock
may jeopardize the preservation of our federal income tax
attributes, including our net operating loss carry-forwards.
Our certificate of incorporation includes transfer
restrictions that may void transactions in our common stock
effected by 5% stockholders.
Our certificate of incorporation places restrictions on transfer
of our equity securities if either (1) the transferor holds
5% or more of the fair market value of all of our issued and
outstanding equity securities or (2) as a result of the
transfer, either any person would become such a 5% stockholder
or the percentage stock ownership of any such 5% stockholder
would be increased. These restrictions are subject to exceptions
described in Description of capital stock. Any
transfer that violates these restrictions will be unwound as
provided in our certificate of incorporation. Moreover, as
indicated below, these provisions may make our stock less
attractive to large institutional holders, and may also
discourage potential acquirers from attempting to take over our
company. As a result, these transfer
21
Risk factors
restrictions may have the effect of delaying or deterring a
change of control of our company and may limit the price that
investors might be willing to pay in the future for shares of
our common stock.
Delaware law, our governing documents and the stock transfer
restriction agreement we entered into as part of our plan of
reorganization may impede or discourage a takeover, which could
adversely affect the value of our common stock.
Provisions of Delaware law, our certificate of incorporation and
the stock transfer restriction agreement with the Union VEBA
Trust may have the effect of discouraging a change of control of
our company or deterring tender offers for our common stock. We
are currently subject to anti-takeover provisions under Delaware
law. These anti-takeover provisions impose various impediments
to the ability of a third party to acquire control of us, even
if a change of control would be beneficial to our existing
stockholders. Additionally, provisions of our certificate of
incorporation and bylaws impose various procedural and other
requirements, which could make it more difficult for
stockholders to effect some corporate actions. For example, our
certificate of incorporation authorizes our board of directors
to determine the rights, preferences and privileges and
restrictions of unissued shares of preferred stock without any
vote or action by our stockholders. Thus, our board of directors
can authorize and issue shares of preferred stock with voting or
conversion rights that could adversely affect the voting or
other rights of holders of common stock. Our certificate of
incorporation also divides our board of directors into three
classes of directors who serve for staggered terms. A
significant effect of a classified board of directors may be to
deter hostile takeover attempts because an acquirer could
experience delays in replacing a majority of directors.
Moreover, stockholders are not permitted to call a special
meeting. As indicated above, our certificate of incorporation
prohibits certain transactions in our common stock involving 5%
stockholders or parties who would become 5% stockholders as a
result of the transaction. In addition, we are party to a stock
transfer restriction agreement with the Union VEBA Trust which
limits its ability to transfer our common stock. The general
effect of the transfer restrictions in the stock transfer
restriction agreement and our certificate of incorporation is to
ensure that a change in ownership of more than 45% of our
outstanding common stock cannot occur in any three-year period.
These rights and provisions may have the effect of delaying or
deterring a change of control of our company and may limit the
price that investors might be willing to pay in the future for
shares of our common stock. See Description of capital
stock.
22
Special note regarding forward-looking statements
This prospectus contains statements which constitute
forward-looking statements within the meaning of the
Private Securities Litigation Reform Act of 1995. These
statements appear throughout this prospectus, including in the
sections entitled Prospectus summary, Risk
factors, Managements discussion and analysis
of financial condition and results of operations, Recent
reorganization, Industry overview and
Business. These forward-looking statements can be
identified by the use of forward-looking terminology such as
believes, expects, may,
estimates, will, should,
plans or anticipates, or the negative of
the foregoing or other variations thereon or comparable
terminology, or by discussions of strategy.
Potential investors are cautioned that any such forward-looking
statements are not guarantees of future performance and involve
significant risks and uncertainties, and that actual results may
vary from those in the forward-looking statements as a result of
various factors. These factors include:
|
|
|
the effectiveness of
managements strategies and decisions;
|
|
|
general economic and business
conditions, including cyclicality and other conditions in the
aerospace and other end markets we serve;
|
|
|
developments in technology;
|
|
|
new or modified statutory or
regulatory requirements;
|
|
|
changing prices and market
conditions; and
|
|
|
the other factors discussed
under Risk factors.
|
Potential investors are urged to consider these factors and the
other factors described under Risk factors carefully
in evaluating any forward-looking statements and are cautioned
not to place undue reliance on these forward-looking statements.
The forward-looking statements included herein are made only as
of the date of this prospectus, and we undertake no obligation
to update any information contained in this prospectus or to
publicly release any revisions to any forward-looking statements
to reflect events or circumstances that occur, or that we become
aware of, after the date of this prospectus.
23
Use of proceeds
All of the shares of common stock offered in this prospectus are
being sold by the selling stockholders. We will not receive any
proceeds from the sale of shares by the selling stockholders.
Dividend policy
We have not declared or paid any cash dividends on our common
stock since we filed chapter 11 bankruptcy in 2002. We
currently intend to retain all earnings for the operation and
expansion of our business and do not currently anticipate paying
any dividends on our common stock. The declaration and payment
of dividends, if any, in the future will be at the discretion of
the board of directors and will be dependent upon our results of
operations, financial condition, cash requirements, future
prospects and other factors. Accordingly, from time to time, the
board may declare dividends, though we can give no assurance in
this regard.
In addition, our revolving credit facility and our term loan
facility restrict our ability to declare or pay, directly or
indirectly, dividends. Under these credit arrangements we may
pay cash dividends only if:
|
|
|
we are not in default or would
not be in default as a result of the dividend; and
|
|
|
the amount of the dividends,
together with the aggregate amount of all other dividend
payments made by us after July 6, 2006, is less than the
sum of (1) 50% of our net income for the period from
July 6, 2006 to the end of our most recently ended fiscal
quarter or if such net income is a deficit, less 100% of such
deficit, (2) up to 100% of the proceeds to us from the sale
or issuance of any of our equity securities remaining after
making any mandatory prepayment under the revolving credit
facility and term loan facility from the proceeds, provided that
the proceeds are not used to make any investments or other
dividend payments, and (3) $2.0 million.
|
We cannot assure you that we will ever pay dividends or, if we
do, as to the amount, frequency or form of any dividends.
Price range of common stock
Our common stock is traded on the Nasdaq Global Market under the
symbol KALU. The following table sets forth the high
and low sales prices of our common stock for each quarterly
period since our common stock began trading on the Nasdaq Global
Market on July 7, 2006:
|
|
|
|
|
|
|
|
|
|
|
High | |
|
Low | |
| |
2006:
|
|
|
|
|
|
|
|
|
Third Quarter 2006 (from July 7, 2006)
|
|
$ |
51.00 |
|
|
$ |
36.50 |
|
Fourth Quarter 2006
|
|
$ |
63.00 |
|
|
$ |
43.00 |
|
2007:
|
|
|
|
|
|
|
|
|
First Quarter 2007 (through January 11, 2007)
|
|
$ |
59.30 |
|
|
$ |
57.18 |
|
|
On January 11, 2007, the last reported sale price for our
common stock on the Nasdaq Global Market was $59.25 per
share. As of December 31, 2006, there were approximately
497 common stockholders of record.
24
Capitalization
The following table sets forth our cash and cash equivalents and
our consolidated capitalization as of September 30, 2006.
You should read this table in conjunction with Selected
historical consolidated financial data,
Managements discussion and analysis of financial
condition and results of operations and our consolidated
financial statements and the notes thereto included elsewhere in
this prospectus.
|
|
|
|
|
|
|
|
|
As of | |
|
|
September 30, | |
|
|
2006 | |
| |
(dollars in millions, except share and per share amounts) |
|
|
Cash and cash equivalents
|
|
$ |
52.7 |
|
|
|
|
|
Debt, including current portion
|
|
|
|
|
|
Revolving credit facility
|
|
$ |
|
|
|
Term loan facility
|
|
|
50.0 |
|
|
Other
|
|
|
|
|
|
|
|
|
|
|
Total debt
|
|
|
50.0 |
|
|
|
|
|
Stockholders equity:
|
|
|
|
|
|
Common stock, $0.01 par value, 45,000,000 shares
authorized; 20,525,660 shares issued and
outstanding(1)
|
|
|
0.2 |
|
|
Additional capital
|
|
|
482.5 |
|
|
Retained earnings
|
|
|
14.3 |
|
|
Common stock owned by the Union VEBA Trust subject to transfer
restrictions, at reorganization value, 6,291,945 shares at
September 30,
2006(2)
|
|
|
(151.1 |
) |
|
|
|
|
|
|
Total stockholders equity
|
|
|
345.9 |
|
|
|
|
|
|
|
Total capitalization
|
|
$ |
395.9 |
|
|
|
|
|
|
|
(1) |
Excludes 1,696,562 shares of common stock reserved and
available for issuance under our equity incentive plan. |
|
(2) |
See Note 7 to our interim consolidated financial
statements for a discussion of the treatment of the Union VEBA
Trusts shares that are subject to transfer
restrictions. |
25
Selected historical consolidated financial data
The following table sets forth selected historical consolidated
financial data for our company. The selected consolidated
statement of income data for the years ended December 31,
2001 and 2002, and the selected consolidated balance sheet data
as of December 31, 2001, 2002 and 2003, are derived from
our audited consolidated financial statements for the years
ended December 31, 2001, 2002 and 2003, which are not
included in this prospectus. The selected consolidated statement
of income data for the years ended December 31, 2003, 2004
and 2005, and the selected consolidated balance sheet data as of
December 31, 2004 and 2005, are derived from our audited
consolidated financial statements included elsewhere in this
prospectus.
As a result of the effectiveness of our plan of reorganization
on July 6, 2006, we adopted fresh start reporting in
accordance with
SOP 90-7 as of
July 1, 2006. Because
SOP 90-7 requires
us to restate our stockholders equity to our
reorganization value and to allocate such value to our assets
and liabilities based on their fair values, our financial
condition and results of operations after June 30, 2006
will not be comparable in some material respects to the
financial condition or results of operations reflected in our
historical financial statements at dates or for periods prior to
July 1, 2006. This makes it difficult to assess our future
prospects based on historical performance.
Our emergence from chapter 11 bankruptcy and the adoption
of fresh start reporting resulted in a new reporting entity for
accounting purposes. Although we emerged from chapter 11
bankruptcy on July 6, 2006, we adopted fresh start
reporting under the provisions of
SOP 90-7 effective
as of the beginning of business on July 1, 2006. As such,
it was assumed that our emergence from chapter 11
bankruptcy was completed instantaneously at the beginning of
business on July 1, 2006 such that all operating activities
during the three months ended September 30, 2006 are
reported as applying to the new reporting entity. We believe
that this is a reasonable presentation as there were no material
transactions between July 1, 2006 and July 6, 2006
other than plan of reorganization-related transactions.
The accompanying financial statements include our financial
statements for both before and after our emergence from
chapter 11 bankruptcy. Financial information related to the
newly emerged entity is generally referred to throughout this
prospectus as successor information and financial
information related to the pre-emergence entity is generally
referred to as predecessor information. The
financial information of the successor entity is not comparable
to that of the predecessor given the effects of the plan of
reorganization, the adoption of fresh start reporting and other
factors.
The selected consolidated financial data as of and for the
nine months ended September 30, 2005 and 2006 are
derived from our unaudited consolidated financial statements
included elsewhere in this prospectus. We have prepared our
unaudited consolidated financial statements on the same basis as
our audited consolidated financial statements (except as set
forth in Note 2 of our interim consolidated financial
statements) and have included all adjustments, consisting of
normal and recurring adjustments, that we consider necessary for
a fair presentation of our financial position and operating
results for the unaudited periods. The selected consolidated
financial and operating data as of and for the nine months
ended September 30, 2005 and 2006 are not necessarily
indicative of the results that may be obtained for a full year.
The following selected consolidated financial data should be
read in conjunction with Managements discussion and
analysis of financial condition and results of operations
and the consolidated financial statements and notes thereto
included elsewhere in this prospectus.
26
Selected historical consolidated financial data
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nine months ended | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
September 30, 2006 | |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Predecessor | |
|
|
|
|
|
|
Predecessor | |
|
period from | |
|
Period from | |
|
|
Predecessor | |
|
nine months | |
|
January 1, | |
|
July 1, 2006 | |
|
|
year ended December 31, | |
|
ended | |
|
2006 | |
|
through | |
|
|
| |
|
September 30, | |
|
to July 1, | |
|
September 30, | |
Statements of income data: |
|
2001(1) | |
|
2002 | |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
2006 | |
|
2006 | |
| |
(dollars in millions, except share and per share data) | |
|
|
|
|
|
|
(unaudited) | |
|
(unaudited) | |
|
(unaudited) | |
|
|
|
|
(restated)(2) | |
|
|
|
|
Net sales
|
|
$ |
889.5 |
|
|
$ |
709.0 |
|
|
$ |
710.2 |
|
|
$ |
942.4 |
|
|
$ |
1,089.7 |
|
|
$ |
815.9 |
|
|
$ |
689.8 |
|
|
$ |
331.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Costs and expenses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cost of products sold
|
|
|
823.4 |
|
|
|
671.4 |
|
|
|
681.2 |
|
|
|
852.2 |
|
|
|
951.1 |
|
|
|
710.9 |
|
|
|
596.4 |
|
|
|
291.8 |
|
|
Depreciation and amortization
|
|
|
32.1 |
|
|
|
32.3 |
|
|
|
25.7 |
|
|
|
22.3 |
|
|
|
19.9 |
|
|
|
15.0 |
|
|
|
9.8 |
|
|
|
2.8 |
|
|
Selling, administrative, research and development, and general
|
|
|
93.7 |
|
|
|
118.6 |
|
|
|
92.5 |
|
|
|
92.3 |
|
|
|
50.9 |
|
|
|
38.0 |
|
|
|
30.3 |
|
|
|
18.0 |
|
|
Other operating charges (credits),
net(3)
|
|
|
30.1 |
|
|
|
31.8 |
|
|
|
141.6 |
|
|
|
793.2 |
|
|
|
8.0 |
|
|
|
6.5 |
|
|
|
0.9 |
|
|
|
(2.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total costs and expenses
|
|
|
979.3 |
|
|
|
854.1 |
|
|
|
941.0 |
|
|
|
1,760.0 |
|
|
|
1,029.9 |
|
|
|
770.4 |
|
|
|
637.4 |
|
|
|
309.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Operating income (loss)
|
|
|
(89.8 |
) |
|
|
(145.1 |
) |
|
|
(230.8 |
) |
|
|
(817.6 |
) |
|
|
59.8 |
|
|
|
45.5 |
|
|
|
52.4 |
|
|
|
21.7 |
|
Other income (expense):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Interest
expense(4)
|
|
|
(106.2 |
) |
|
|
(19.0 |
) |
|
|
(9.1 |
) |
|
|
(9.5 |
) |
|
|
(5.2 |
) |
|
|
(4.2 |
) |
|
|
(0.8 |
) |
|
|
|
|
|
Reorganization
items(5)
|
|
|
|
|
|
|
(33.3 |
) |
|
|
(27.0 |
) |
|
|
(39.0 |
) |
|
|
(1,162.1 |
) |
|
|
(25.3 |
) |
|
|
3,093.1 |
|
|
|
|
|
|
Other, net
|
|
|
(68.7 |
) |
|
|
(0.9 |
) |
|
|
(5.2 |
) |
|
|
4.2 |
|
|
|
(2.4 |
) |
|
|
(1.5 |
) |
|
|
1.2 |
|
|
|
0.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) before income taxes and discontinued operations
|
|
|
(264.7 |
) |
|
|
(198.3 |
) |
|
|
(272.1 |
) |
|
|
(861.9 |
) |
|
|
(1,109.9 |
) |
|
|
14.5 |
|
|
|
3,145.9 |
|
|
|
22.6 |
|
Provision for income taxes
|
|
|
(523.4 |
) |
|
|
(4.4 |
) |
|
|
(1.5 |
) |
|
|
(6.2 |
) |
|
|
(2.8 |
) |
|
|
(6.0 |
) |
|
|
(6.2 |
) |
|
|
(8.3 |
) |
Minority interests
|
|
|
(0.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations
|
|
|
(788.3 |
) |
|
|
(202.7 |
) |
|
|
(273.6 |
) |
|
|
(868.1 |
) |
|
|
(1,112.7 |
) |
|
|
8.5 |
|
|
|
3,139.7 |
|
|
|
14.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Discontinued operations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations, net of income taxes,
including minority interests
|
|
|
165.3 |
|
|
|
(266.0 |
) |
|
|
(514.7 |
) |
|
|
(5.3 |
) |
|
|
(2.5 |
) |
|
|
21.3 |
|
|
|
4.3 |
|
|
|
|
|
|
Gain from sale of commodity interests
|
|
|
163.6 |
|
|
|
|
|
|
|
|
|
|
|
126.6 |
|
|
|
366.2 |
|
|
|
365.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued
operations(6)
|
|
|
328.9 |
|
|
|
(266.0 |
) |
|
|
(514.7 |
) |
|
|
121.3 |
|
|
|
363.7 |
|
|
|
386.9 |
|
|
|
4.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cumulative effect on years prior to 2005 of adopting accounting
for conditional asset retirement obligations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(4.7 |
) |
|
|
(4.7 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
(459.4 |
) |
|
$ |
(468.7 |
) |
|
$ |
(788.3 |
) |
|
$ |
(746.8 |
) |
|
$ |
(753.7 |
) |
|
$ |
390.7 |
|
|
$ |
3,144.0 |
|
|
$ |
14.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Earnings (loss) per share
basic(7):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations
|
|
$ |
(9.82 |
) |
|
$ |
(2.52 |
) |
|
$ |
(3.41 |
) |
|
$ |
(10.88 |
) |
|
$ |
(13.97 |
) |
|
$ |
0.11 |
|
|
$ |
39.42 |
|
|
$ |
0.72 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations
|
|
$ |
4.09 |
|
|
$ |
(3.30 |
) |
|
$ |
(6.42 |
) |
|
$ |
1.52 |
|
|
$ |
4.57 |
|
|
$ |
4.85 |
|
|
$ |
0.05 |
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from cumulative effect on years prior to 2005 of adopting
accounting for conditional asset retirement obligations
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
(0.06 |
) |
|
$ |
(0.06 |
) |
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
(5.73 |
) |
|
$ |
(5.82 |
) |
|
$ |
(9.83 |
) |
|
$ |
(9.36 |
) |
|
$ |
(9.46 |
) |
|
$ |
4.90 |
|
|
$ |
39.47 |
|
|
$ |
0.72 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Earnings (loss) per
sharediluted(7):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations
|
|
$ |
(9.82 |
) |
|
$ |
(2.52 |
) |
|
$ |
(3.41 |
) |
|
$ |
(10.88 |
) |
|
$ |
(13.97 |
) |
|
$ |
0.11 |
|
|
$ |
39.42 |
|
|
$ |
0.72 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations
|
|
$ |
4.09 |
|
|
$ |
(3.30 |
) |
|
$ |
(6.42 |
) |
|
$ |
1.52 |
|
|
$ |
4.57 |
|
|
$ |
4.85 |
|
|
$ |
0.05 |
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from cumulative effect on years prior to 2005 of adopting
accounting for conditional asset retirement obligations
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
(0.06 |
) |
|
$ |
(0.06 |
) |
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss)
|
|
$ |
(5.73 |
) |
|
$ |
(5.82 |
) |
|
$ |
(9.83 |
) |
|
$ |
(9.36 |
) |
|
$ |
(9.46 |
) |
|
$ |
4.90 |
|
|
$ |
39.47 |
|
|
$ |
0.72 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Dividends per common share
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares outstanding (in thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
80,235 |
|
|
|
80,578 |
|
|
|
80,175 |
|
|
|
79,815 |
|
|
|
79,675 |
|
|
|
79,676 |
|
|
|
79,672 |
|
|
|
20,002 |
|
|
Diluted
|
|
|
80,235 |
|
|
|
80,578 |
|
|
|
80,175 |
|
|
|
79,815 |
|
|
|
79,675 |
|
|
|
79,676 |
|
|
|
79,672 |
|
|
|
20,029 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(footnotes on following page) |
27
Selected historical consolidated financial data
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31, | |
|
As of September 30, | |
|
|
| |
|
| |
Balance sheet data: |
|
2001 | |
|
2002 | |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
2006 | |
| |
(dollars in millions) |
|
|
|
|
|
|
|
|
(unaudited) | |
|
|
|
|
(restated)(2) | |
|
|
Cash and cash equivalents
|
|
$ |
154.1 |
|
|
$ |
77.4 |
|
|
$ |
35.5 |
|
|
$ |
55.4 |
|
|
$ |
49.5 |
|
|
$ |
43.3 |
|
|
$ |
52.7 |
|
Working
capital(8)
|
|
|
(44.2 |
) |
|
|
183.0 |
|
|
|
104.9 |
|
|
|
73.0 |
|
|
|
119.7 |
|
|
|
85.6 |
|
|
|
212.1 |
|
Total assets
|
|
|
2,743.7 |
|
|
|
2,225.4 |
|
|
|
1,623.5 |
|
|
|
1,882.4 |
|
|
|
1,538.9 |
|
|
|
2,197.8 |
|
|
|
621.1 |
|
Long-term debt
|
|
|
678.7 |
|
|
|
20.7 |
|
|
|
2.2 |
|
|
|
2.8 |
|
|
|
1.2 |
|
|
|
1.2 |
|
|
|
50.0 |
|
Stockholders equity (deficit)
|
|
|
(441.1 |
) |
|
|
(1,085.6 |
) |
|
|
(1,738.7 |
) |
|
|
(2,384.2 |
) |
|
|
(3,141.2 |
) |
|
|
(1,993.5 |
) |
|
|
345.9 |
|
|
|
(1) |
Statement of income data and balance sheet data for 2001
reflect our financial results and position prior to our filing
for chapter 11 bankruptcy in February 2002. Such data
includes the impact of our concluding a valuation allowance was
required in respect of recorded tax attributes and from the
partial sale of one of our commodity-related interests. |
|
(2) |
We restated our operating results for the nine months ended
September 30, 2005. See Note 15 to our interim
consolidated financial statements for information regarding the
restatement. |
|
(3) |
Other operating charges (credits), net in 2003 and 2004
include certain significant charges associated with the
termination of certain pension and post-retirement medical
plans, a settlement in respect of a past labor matter and other
items. These items are detailed in Note 6 to our audited
consolidated financial statements and Note 10 to our
interim consolidated financial statements. |
|
(4) |
Excludes unrecorded contractual interest expense of
$84.0 million in 2002, $95.0 million in each of 2003,
2004 and 2005, $71.2 million for the nine months ended
September 30, 2005 and $47.4 million for the period
from January 1, 2006 to July 1, 2006. |
|
(5) |
Reorganization items for 2005 include an approximate
$1.1 billion charge as a result of the value of an
intercompany note treated as being for the benefit of certain
creditors. See Note 1 to our audited consolidated financial
statements. Reorganization items for the period from
January 1, 2006 to July 1, 2006 include a gain of
approximately $3.1 billion in connection with the
implementation of our plan of reorganization and fresh start
reporting. See Note 13 to our interim consolidated
financial statements. |
|
(6) |
Income (loss) from discontinued operations includes the
operating results associated with commodity interests sold as
well as certain significant gains and losses associated with the
dispositions. See Note 3 to our audited consolidated
financial statements for information in respect of 2003, 2004
and 2005. |
|
(7) |
Earnings (loss) per share and share information prior to our
emergence from chapter 11 bankruptcy may not be meaningful
because, pursuant to our plan of reorganization, on July 6,
2006, all outstanding equity interests were cancelled without
consideration. |
|
(8) |
Working capital represents total current assets, including
cash, minus total current liabilities. |
28
Managements discussion and analysis of financial condition
and results of operations
You should read the following discussion together with the
consolidated financial statements and the notes thereto included
elsewhere in this prospectus. This discussion contains
forward-looking statements within the meaning of the
Private Securities Litigation Reform Act of 1995. The cautionary
statements made in this prospectus should be read as applying to
all related forward-looking statements wherever they appear in
this prospectus. Forward-looking statements are not guarantees
of future performance and involve significant risks and
uncertainties. Actual results may vary from those in
forward-looking statements as a result of a number of factors,
including those we discuss under Risk factors and
elsewhere in this prospectus. You should read Risk
factors and Special note regarding forward-looking
statements.
In the discussion of operating results below, certain items
are referred to as non-run-rate items. For purposes of such
discussion, non-run-rate items are items that, while they may
recur from period to period, are (1) particularly material
to results, (2) affect costs as a result of external market
factors, and (3) may not recur in future periods if the
same level of underlying performance were to occur. Non-run-rate
items are part of our business and operating environment but are
worthy of being highlighted for benefit of the users of the
financial statements. Our intent is to allow users of the
financial statements to consider our results both in light of
and separately from fluctuations in underlying metal prices.
The following discussion gives effect to the restatement
discussed in Note 15 of our notes to interim consolidated
financial statements.
OVERVIEW
Our primary line of business is the production and sale of
fabricated aluminum products. In addition, we own a 49% interest
in Anglesey, an aluminum smelter. Historically, we operated in
all principal sectors of the aluminum industry including the
production and sale of bauxite, alumina and primary aluminum in
domestic and international markets. However, as a part of our
chapter 11 bankruptcy reorganization, we sold substantially all
of our commodities operations other than Anglesey. The balances
and results of operations in respect of the commodities
interests sold (including our interests in and related to
Queensland Alumina Limited, or QAL, sold in April 2005) are now
considered discontinued operations.
Changes in global, regional or country-specific economic
conditions can have a significant impact on overall demand for
aluminum-intensive fabricated products in the markets for our
Aero/HS, general engineering and custom automotive and
industrial products. These changes in demand can directly affect
our earnings by impacting the overall volume and mix of our
fabricated products sold.
Changes in primary aluminum prices also affect our primary
aluminum business unit and expected earnings under fixed price
fabricated products contracts. We manage the risk of
fluctuations in the price of primary aluminum through a
combination of pricing policies, internal hedging and financial
derivatives. Our operating results are also, albeit to a lesser
degree, sensitive to changes in prices for power and natural gas
and changes in certain foreign exchange rates. All of the
foregoing have been subject to significant price fluctuations
over recent years. For a discussion of the possible impacts of
our chapter 11 bankruptcy reorganization on our sensitivity to
changes in market conditions, see Quantitative and
Qualitative Disclosures about Market Risks
Sensitivity.
During the nine months ended September 30, 2005, the
average London Metal Exchange transaction price, or LME price,
per pound of primary aluminum was $0.83. During the nine months
ended
29
Managements discussion and analysis of financial
condition and results of operations
September 30, 2006, the average LME price per pound for
primary aluminum was approximately $1.14. At October 31,
2006, the LME price per pound was approximately $1.29.
Emergence from chapter 11 bankruptcy
During the past four years, we operated under chapter 11 of
the United States Bankruptcy Code under the supervision of the
United States Bankruptcy Court for the District of Delaware. We
emerged from chapter 11 bankruptcy on July 6, 2006.
Pursuant to our plan of reorganization:
|
|
|
all of our material pre-petition
debt, pension and post-retirement medical obligations and
asbestos and other tort liabilities, along with other
pre-petition claims (which aggregated in our June 30, 2006
balance sheet to approximately $4.4 billion) were addressed
and resolved; and
|
|
|
all of the equity interests of
our pre-emergence stockholders were cancelled without
consideration and our post-emergence equity was issued and
delivered to a third party disbursing agent for distribution to
certain claimholders.
|
Please see Recent reorganization Corporate
Structure for a diagram of our simplified post-emergence
corporate structure.
Impacts of emergence from chapter 11 bankruptcy on
future financial statements
All financial statement information as of June 30, 2006 and
for all prior periods relates to our company before emergence
from chapter 11 bankruptcy. Our financial statements for
the quarter ending September 30, 2006 are the first set of
financial statements that reflect financial information after
our emergence. As more fully discussed below, there will be a
number of differences between our financial statements before
and after emergence that will make comparisons of our future and
past financial information difficult to make.
As a result of our emergence from chapter 11 bankruptcy, we
have applied fresh start reporting to our opening July 1,
2006 consolidated balance sheet as required by generally
accepted accounting principles. As such, we have taken the
following steps:
|
|
|
We have adjusted our
stockholders equity to equal the reorganization value of
our company;
|
|
|
We have reset items such as
accumulated depreciation, accumulated deficit and accumulated
other comprehensive income (loss) to zero; and
|
|
|
We have allocated the
reorganization value to our individual assets and liabilities
based on their estimated fair value. Such items as current
liabilities, accounts receivable, and cash reflect values
similar to those reported prior to emergence. Items such as
inventory, property, plant and equipment, long-term assets and
long-term liabilities have been significantly adjusted from
amounts previously reported. As more fully discussed in the
notes to our financial statements, these adjustments may
adversely affect our future results.
|
We also made post-emergence changes to our accounting policies
and procedures. In general, our accounting policies are the same
as or are similar to those we have historically used to prepare
our financial statements. In certain cases, however, we have
adopted different accounting policies or applied methodologies
differently to our post-emergence financial statement
information. For instance, we changed our accounting
methodologies with respect to inventory accounting. While we
will account for inventories on a LIFO basis after emergence, we
are applying LIFO differently than we did in the past.
Specifically, we will view each quarter on a standalone basis
for computing LIFO; whereas in the past we recorded LIFO amounts
with a view to the entire fiscal year which, with certain
exceptions, tended to result in LIFO charges being recorded in
the fourth quarter or second half of the year.
30
Managements discussion and analysis of financial
condition and results of operations
Additionally, certain items such as earnings per share and
Statement of Financial Accounting Standards No. 123
(revised 2004), Share-Based Payment, which had few, if any,
implications while we were in chapter 11 bankruptcy will
have increased importance in our future financial statement
information.
Capital structure
After emergence from chapter 11 bankruptcy
On the July 6, 2006 effective date of our plan of
reorganization, pursuant to the plan, all equity interests held
by our stockholders immediately prior to the effective date were
cancelled without consideration, and we issued 20,000,000 new
shares of common stock to a third-party disbursing agent for
distribution in accordance with our plan of reorganization. Of
such 20,000,000 new shares, a total of 8,809,900 shares
were distributed to, and are currently held by, the Union VEBA
Trust. As of December 31, 2006, there were also outstanding
525,660 shares that were issued to our employees and
directors under our equity incentive plan on and after the
effective date of our plan of reorganization. As a result, the
Union VEBA Trust held approximately 42.9% of our outstanding
common stock as of December 31, 2006. See Recent
reorganization and Principal and selling
stockholders. There are restrictions on the transfer of
our common stock. In addition, under our revolving credit
facility and term loan facility, there are restrictions on our
purchase of common stock and limitations on our ability to pay
dividends. See Description of capital stock and
Liquidity and Capital Resources
Financing facilities After emergence from
chapter 11 bankruptcy for more detailed discussions
of these restrictions.
Prior to emergence from chapter 11 bankruptcy
Prior to the effective date of our plan of reorganization,
MAXXAM Inc. and one of its wholly-owned subsidiaries
collectively owned approximately 63% of our common stock, with
the remaining approximately 37% of our common stock being
publicly held. However, as discussed in Note 2 to our
interim consolidated financial statements, pursuant to our plan
of reorganization, all equity interests held by our stockholders
immediately prior to the effective date of our plan of
reorganization were cancelled without consideration upon our
emergence from chapter 11 bankruptcy.
31
Managements discussion and analysis of financial
condition and results of operations
RESULTS OF OPERATIONS
Our main line of business is the production and sale of
fabricated aluminum products. In addition, we own a 49% interest
in Anglesey, which owns and operates an aluminum smelter in
Holyhead, Wales.
The table below provides selected operational and financial
information on a consolidated basis with respect to the fiscal
years ended December 31, 2003, 2004 and 2005 and the nine
months ended September 30, 2005 and 2006 (unaudited
in millions of dollars, except shipments and prices). The
following data should be read in conjunction with our
consolidated financial statements and the notes thereto
contained elsewhere in this prospectus. Interim results are not
necessarily indicative of those for a full year.
Our emergence from chapter 11 bankruptcy and the adoption
of fresh start reporting resulted in a new reporting entity for
accounting purposes. Although we emerged from chapter 11
bankruptcy on July 6, 2006, we adopted fresh start
reporting under the provisions of SOP 90-7, effective as of
the beginning of business on July 1, 2006. As such, it was
assumed that our emergence from chapter 11 bankruptcy was
completed instantaneously at the beginning of business on
July 1, 2006 so that all operating activities during the
three months ended September 30, 2006 are reported as
applying to the new reporting entity. We believe that this is a
reasonable presentation as there were no material transactions
between July 1, 2006 and July 6, 2006 other than plan
of reorganization related transactions.
The selected operational and financial information after the
effective date of our plan of reorganization are those of the
successor and are not comparable to those of the predecessor.
However, for purposes of this discussion (in the table below),
the successors results for the period from July 1,
2006 through September 30, 2006 have been combined with the
predecessors results for the period from January 1,
2006 to July 1, 2006 and are compared to the
predecessors results for the nine months ended
September 30, 2005. Differences between periods due to
fresh start reporting are explained when material.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nine months ended | |
|
|
Year ended December 31, | |
|
September 30, | |
|
|
| |
|
| |
Operating data (unaudited) |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
2006 | |
| |
Shipments (millions of pounds):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated products
|
|
|
372.3 |
|
|
|
458.6 |
|
|
|
481.9 |
|
|
|
365.2 |
|
|
|
399.7 |
|
|
Primary aluminum
|
|
|
158.7 |
|
|
|
156.6 |
|
|
|
155.6 |
|
|
|
115.7 |
|
|
|
117.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
|
531.0 |
|
|
|
615.2 |
|
|
|
637.5 |
|
|
|
480.9 |
|
|
|
516.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Average realized third party sales price (per pound):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated
products(2)
|
|
$ |
1.61 |
|
|
$ |
1.76 |
|
|
$ |
1.95 |
|
|
$ |
1.94 |
|
|
$ |
2.18 |
|
|
Primary
aluminum(3)
|
|
$ |
0.71 |
|
|
$ |
0.85 |
|
|
$ |
0.95 |
|
|
$ |
0.93 |
|
|
$ |
1.27 |
|
(footnotes on following page) |
32
Managements discussion and analysis of financial
condition and results of operations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nine months ended | |
|
|
Year ended December 31, | |
|
September 30, | |
|
|
| |
|
| |
Statements of income data: |
|
2003 | |
|
2004 | |
|
2005 | |
|
2005 | |
|
2006 | |
| |
(dollars in millions) | |
|
|
|
|
(unaudited) | |
|
|
(Restated)(1) | |
|
|
Net sales:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated products
|
|
$ |
597.8 |
|
|
$ |
809.3 |
|
|
$ |
939.0 |
|
|
$ |
707.7 |
|
|
$ |
872.5 |
|
|
Primary aluminum
|
|
|
112.4 |
|
|
|
133.1 |
|
|
|
150.7 |
|
|
|
108.2 |
|
|
|
148.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total net sales
|
|
$ |
710.2 |
|
|
$ |
942.4 |
|
|
$ |
1,089.7 |
|
|
$ |
815.9 |
|
|
$ |
1,021.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Segment operating income
(loss)(1):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fabricated
products(4)(5)
|
|
$ |
(21.2 |
) |
|
$ |
33.0 |
|
|
$ |
87.2 |
|
|
$ |
66.3 |
|
|
$ |
90.3 |
|
|
Primary
aluminum(6)
|
|
|
6.7 |
|
|
|
13.9 |
|
|
|
16.4 |
|
|
|
13.4 |
|
|
|
15.2 |
|
|
Corporate and other
|
|
|
(74.7 |
) |
|
|
(71.3 |
) |
|
|
(35.8 |
) |
|
|
(27.7 |
) |
|
|
(33.4 |
) |
|
Other operating credits (charges), net
(7)
|
|
|
(141.6 |
) |
|
|
(793.2 |
) |
|
|
(8.0 |
) |
|
|
(6.5 |
) |
|
|
2.0 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total operating income (loss)
|
|
$ |
(230.8 |
) |
|
$ |
(817.6 |
) |
|
$ |
59.8 |
|
|
$ |
45.5 |
|
|
$ |
74.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reorganization
items(8)
|
|
$ |
(27.0 |
) |
|
$ |
(39.0 |
) |
|
$ |
(1,162.1 |
) |
|
$ |
(25.3 |
) |
|
$ |
3,093.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations
(9)
|
|
$ |
(514.7 |
) |
|
$ |
121.3 |
|
|
$ |
363.7 |
|
|
$ |
386.9 |
|
|
$ |
4.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cumulative effect on years prior to 2005 of adopting accounting
for conditional asset retirement
obligation(10)
|
|
$ |
|
|
|
$ |
|
|
|
$ |
(4.7 |
) |
|
$ |
(4.7 |
) |
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income
(loss)(1)
|
|
$ |
788.3 |
|
|
$ |
(746.8 |
) |
|
$ |
(753.7 |
) |
|
$ |
390.7 |
|
|
$ |
3,158.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital expenditures, net of accounts payable (excluding
discontinued operations)
|
|
$ |
8.9 |
|
|
$ |
7.6 |
|
|
$ |
31.0 |
|
|
$ |
20.4 |
|
|
$ |
39.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
We restated our operating results for the nine months ended
September 30, 2005. See Note 15 to our interim
consolidated financial statements for information regarding the
restatement. |
|
(2) |
Average realized prices for our fabricated products business
unit are subject to fluctuations due to changes in product mix
as well as underlying primary aluminum prices and are not
necessarily indicative of changes in underlying
profitability. |
|
(3) |
Average realized prices for our primary aluminum business
unit exclude hedging revenues. |
|
(4) |
Operating results for the nine months ended September 30,
2005 include metal losses of $2.3 million. Operating
results for the nine months ended September 30, 2006
include a non-cash LIFO inventory charge of $18.4 million
and metal profits of approximately $13.9 million. |
|
(5) |
Includes non-cash mark-to-market losses of $1.5 million
in the nine months ended September 30, 2006. For further
discussion regarding mark-to-market matters, see Note 9 to
our interim consolidated financial statements. |
|
(6) |
Includes non-cash
mark-to-market gains
(losses) totaling $(4.5) million and $8.1 million in
the nine months ended September 30, 2005 and 2006,
respectively. For further discussion regarding mark-to-market
matters, see Note 9 to our interim consolidated financial
statements. |
|
(7) |
Other operating credits (charges), net in 2003 and 2004
include certain significant charges associated with the
termination of certain pension and post-retirement medical
plans, a settlement in respect of a past labor matter and other
items. These items are detailed in Note 6 to our audited
consolidated financial statements. |
|
(8) |
Reorganization items for 2005 includes an approximate
$1.1 billion charge as a result of the value of an
intercompany note treated as being for the benefit of certain
creditors. See Note 1 to |
33
Managements discussion and analysis of financial
condition and results of operations
|
|
|
our audited consolidated financial statements. Reorganization
items for the period from January 1, 2006 to July 1,
2006 includes a gain of approximately $3.1 billion in
connection with the implementation of our plan of reorganization
and fresh start reporting. See Note 13 to our interim
consolidated financial statements. |
|
(9) |
Income (loss) from discontinued operations includes a
substantial impairment charge in 2003 and gains in 2004 and 2005
in connection with the sale of certain of our commodity-related
interests. See Note 3 to our audited consolidated financial
statements. |
|
|
(10) |
See Note 2 to our interim consolidated financial
statements for a discussion of the change in accounting for
conditional asset retirement obligations. |
NINE MONTHS ENDED SEPTEMBER 30, 2006 COMPARED TO NINE
MONTHS ENDED SEPTEMBER 30, 2005
Summary
For the nine months ended September 30, 2006, we reported
net income of $3,158.3 million, compared to net income of
$390.7 million for the same period in 2005. Net income for
the nine months ended September 30, 2006 includes a
non-cash gain of $3,113.1 million related to the
implementation of our plan of reorganization and the adoption of
fresh start reporting. Net income for the nine months ended
September 30, 2005 includes $365.6 million related to
the gain on the sale of QAL and favorable QAL operating results
prior to the sale of our QAL-related interests on April 1,
2005. In addition, the nine months ended September 30, 2005
and 2006 include a number of non-run-rate items that are more
fully explained in the section below.
Net sales for the nine months ended September 30, 2006
totaled $1,021.2 million compared to $815.9 million
for the nine months ended September 30, 2005. As more fully
discussed below, the increase in net sales is primarily the
result of the increase in the market price for primary aluminum.
Increases in the market price for primary aluminum do not
necessarily directly translate to increased profitability
because (1) a substantial portion of the primary aluminum
price increases and decreases experienced by our fabricated
products business is passed on directly to customers and
(2) our hedging activities, while limiting our risk of
losses, also limit our ability to participate in price increases.
Fabricated aluminum products
For the nine month period ended September 30, 2006, net
sales of fabricated products increased by 23% to
$872.5 million as compared to the same period in 2005,
primarily due to a 12% increase in average realized prices and a
9% increase in shipments. The increase in the average realized
prices primarily reflects higher underlying primary aluminum
prices. The increase in volume in 2006 was led by aerospace and
defense-related shipments. Shipments improved for all broad
product lines in the nine months ended September 30, 2006.
Operating income for the nine months ended September 30,
2006 of $90.3 million was approximately $24 million
higher than the prior year period. Operating income for the nine
months ended September 30, 2006 also included an
approximate $28 million favorable impact compared to the
prior year from higher shipments, stronger conversion prices
(representing the value added from the fabrication process) and
favorable scrap raw material costs. Higher energy prices had an
approximate $4 million adverse impact on the nine months
ended September 30, 2006 versus the nine months ended
September 30, 2005, but a majority of this impact was
offset by favorable cost performance. Major maintenance costs
during the nine months ended September 30, 2006 were
comparable to the same period in 2005. Depreciation and
amortization in the nine months ended September 30, 2006
was approximately $2.2 million lower than the prior year
period as a result of the adoption of fresh start reporting.
34
Managements discussion and analysis of financial
condition and results of operations
Both the nine months ended September 30, 2005 and 2006
include non-run-rate items. These items, which are listed below,
had a combined approximate $6.0 million adverse impact on
the nine months ended September 30, 2006, which is
approximately $3.7 million worse than the comparable prior
year period:
|
|
|
Metal profits in the nine months
ended September 30, 2006 (before considering LIFO
implications) of approximately $13.9 million, which is
approximately $16.2 million better than the prior year
period.
|
|
|
A non-cash LIFO inventory charge
of $18.4 million in the nine months ended
September 30, 2006. There were no LIFO charges or benefits
in the comparable 2005 period.
|
|
|
Mark-to-market charges on energy
hedging in the nine months ended September 30, 2006 were
approximately $1.5 million. During the nine months ended
September 30, 2005, there were no mark-to-market charges or
gains.
|
Segment operating results for 2006 and 2005 include gains on
intercompany hedging activities with the primary aluminum
business unit totaling $31.5 million for the nine months
ended September 30, 2006 and $3.4 million for the nine
months ended September 30, 2005. These amounts eliminate in
consolidation. Operating results for our fabricated products
segment for the nine months ended September 30, 2005
exclude defined contribution savings plan charges of
approximately $5.4 million.
The first furnace added as a part of the $105 million
expansion project at our Trentwood facility has reached full
production. A second furnace that is a part of the Trentwood
expansion has begun production and is expected to ramp up to
full production no later than early 2007. The third furnace
expansion and the addition of the stretcher, which will enable
us to produce heavier gauge plate products, are both expected to
be on-line by early 2008. The additional production capacity
from the first two furnace expansions has provided the
opportunity for increased aerospace and defense-related
shipments beginning in the fourth quarter of 2006 and should
help offset the potential for lackluster automotive-related
shipments due to the current industry decline in automotive
sales.
Primary aluminum
During the nine months ended September 30, 2006,
third-party net sales of primary aluminum increased 37%,
compared to the same period in 2005. The increase was almost
entirely attributable to the increase in average realized
primary aluminum prices.
The following table sets forth (in millions of dollars) the
differences in the major components of operating results for our
primary aluminum segment between the nine months ended
September 30, 2006 and the corresponding prior year period,
as well as the primary factors leading to such differences. Many
of the factors indicated are items that are subject to
significant fluctuation from period to period and are largely
impacted by items outside managements control.
35
Managements discussion and analysis of financial
condition and results of operations
|
|
|
|
|
|
|
|
|
|
|
|
|
Nine months ended | |
|
|
|
|
September 30, | |
|
|
|
|
2006 vs. 2005 | |
|
|
|
|
| |
|
|
|
|
Operating | |
|
Better | |
|
|
Component |
|
income | |
|
(worse) | |
|
Factor |
|
Sales of production from Anglesey
|
|
$ |
38 |
|
|
$ |
15 |
|
|
Market price for primary aluminum |
Internal hedging with fabricated products segment
|
|
|
(32 |
) |
|
|
(29 |
) |
|
Eliminates in consolidation |
Derivative settlements
|
|
|
1 |
|
|
|
3 |
|
|
Impacted by positions and market prices |
Mark-to-market on derivative instruments
|
|
|
8 |
|
|
|
13 |
|
|
Impacted by positions and market prices |
|
|
|
|
|
|
|
|
|
|
|
$ |
15 |
|
|
$ |
2 |
|
|
|
|
|
|
|
|
|
|
|
|
The improvement in Anglesey-related results, as well as the
offsetting adverse internal hedging results, in the nine months
ended September 30, 2006 over the comparable 2005 period
was driven primarily by increases in primary aluminum market
prices. The primary aluminum market-driven improvement in
Anglesey-related operating results was offset by an approximate
15% contractual increase in Angleseys power costs
affecting the 2006 period, an increase of approximately
$1 million per quarter. Beginning in the second quarter of
2006, the Anglesey-related results were adversely affected
(versus 2005) by a 20% increase in contractual alumina costs
related to a new alumina purchase contract that runs through
2007. Power and alumina costs, in general, represent
approximately two-thirds of Angleseys costs, and as such,
future results will be adversely affected by these changes. The
nuclear plant that supplies power to Anglesey is currently
slated for decommissioning in late 2010. For Anglesey to be able
to operate past September 2009 when its current power contract
expires, Anglesey will have to secure a new or alternative power
contract at prices that make its operation viable. We cannot
assure you that Anglesey will be successful in this regard.
In addition, given the potential for future shutdown and related
costs, dividends from Anglesey have been suspended while
Anglesey studies future cash requirements. Dividends over the
past five years have fluctuated substantially depending on
various operational and market factors. During the last five
years and the nine months ended September 30, 2006, cash
dividends received were as follows (in millions of dollars):
2001 $2.8, 2002 $6.0, 2003
$4.3, 2004 $4.5, 2005 $9.0, and
2006 $11.7.
Corporate and other
Corporate operating expenses represent corporate general and
administrative expenses that are not allocated to our business
segments. Corporate operating expenses for the nine months ended
September 30, 2006 were approximately $5.7 million
higher than the comparable period in 2005. Incentive
compensation accruals were approximately $5.0 million
higher than the nine months ended September 30, 2005,
including a $2.2 million non-cash charge associated with
vested and non-vested stock grants. Additionally, we incurred
certain costs we considered largely non-run-rate, including
$1.8 million of preparation costs related to the
Sarbanes-Oxley Act of 2002, $0.7 million of higher
post-emergence tax service/preparation costs and
$1.1 million of costs associated with certain computer
upgrades. The remaining change in the nine months ended
September 30, 2006 primarily reflects lower salary and
other costs related to the movement toward a post-emergence
structure.
Once the activity with our emergence from chapter 11
bankruptcy, which will continue through early 2007, and
incremental Sarbanes-Oxley-related activities are complete, we
expect there will be a substantial decline in corporate and
other operating costs.
36
Managements discussion and analysis of financial
condition and results of operations
Corporate operating results for the nine months ended
September 30, 2005, discussed above, exclude defined
contribution savings plan charges of approximately
$0.5 million.
Discontinued operations
Operating results from discontinued operations for the nine
months ended September 30, 2006 consist of a
$7.5 million payment from an insurer for certain residual
claims we had in respect of a 2000 incident at our Gramercy,
Louisiana alumina facility, which was sold in 2004, and a
$1.1 million surcharge refund related to certain energy
surcharges, which have been pending for a number of years,
offset, in part, by a $5.0 million charge resulting from an
agreement between us and the Bonneville Power Administration for
an electric power contract rejected in connection with our
chapter 11 bankruptcy. Operating results from discontinued
operations for the nine months ended September 30, 2005
include the $365.6 million gain resulting from the sale of
our interests in and related to QAL on April 1, 2005 and
the favorable QAL operating results prior to the sale of our
QAL-related interests.
Reorganization items
Reorganization items increased substantially in the nine months
ended September 30, 2006 as compared to the comparable
periods in 2005 as a result of the non-cash gain on the
implementation of our plan of reorganization and the application
of fresh start reporting of approximately $3,113.1 million
in the third quarter of 2006.
YEAR ENDED DECEMBER 31, 2005 COMPARED TO YEAR ENDED
DECEMBER 31, 2004
We reported a net loss of $753.7 million in 2005 compared
to a net loss of $746.8 million in 2004. Net sales in 2005
totaled $1,089.7 million compared to $942.4 million
in 2004.
Fabricated aluminum products
Net sales of fabricated products increased by 16% during 2005 as
compared to 2004 primarily due to a 10% increase in average
realized prices and a 6% increase in shipments. The increase in
the average realized prices reflected (in relatively equal
proportions) higher conversion prices and higher underlying
primary aluminum prices. The higher conversion prices were
primarily attributable to continued strength in fabricated
aluminum product markets, particularly for Aero/ HS products, as
well as a favorable mix in the type of Aero/ HS products in the
early part of 2005. Current period shipments were higher than
2004 shipments due primarily to the increased Aero/ HS product
demand.
Segment operating results (before other operating charges, net)
for 2005 improved over 2004 by approximately $54 million.
The improvement consisted of improved sales performance
(primarily due to factors cited above) of $64 million
offset by higher operating costs, particularly for natural gas.
Higher natural gas prices had a particularly significant impact
on the fourth quarter of 2005. As of March 2006, natural gas
prices had decreased somewhat but had not decreased to the price
level experienced during the first nine months of 2005. Lower
2005 charges for legacy pension and retiree medical-related
costs of $5 million were largely offset by other cost
increases versus 2004, including $6 million of higher
non-cash LIFO inventory charges, which were $9 million in
2005 versus $3.2 million in 2004. Segment operating results
for 2005 and 2004 included gains on intercompany hedging
activities with our primary aluminum business which totaled
$11.1 million and $8.6 million, respectively. These
amounts eliminate in consolidation.
Segment operating results for 2005, discussed above, excluded
deferred contribution savings plan charges of approximately
$6.3 million.
37
Managements discussion and analysis of financial
condition and results of operations
Primary aluminum
Third-party net sales of primary aluminum in 2005 increased by
approximately 13% as compared to 2004. The increase was almost
entirely attributable to the increase in average realized
primary aluminum prices.
Segment operating results for 2005 included approximately
$32 million related to the sale of primary aluminum
resulting from our ownership interests in Anglesey offset by
(1) losses on intercompany hedging activities with our
fabricated products business (which eliminate in consolidation)
which totaled approximately $11.1 million, and
(2) approximately $4.1 million of non-cash charges
associated with the discontinuance of hedge accounting treatment
of derivative instruments as more fully discussed in
Notes 2, 12 and 16 to our audited consolidated financial
statements. Primary aluminum hedging transactions with third
parties were essentially neutral in 2005. In 2004, segment
operating results consisted of approximately $21 million
related to sales of primary aluminum resulting from our
ownership interests in Anglesey and approximately
$2 million of gains from third-party hedging activities,
offset by approximately $8.6 million of losses on
intercompany hedging activities with our fabricated products
business (which eliminate in consolidation). The improvement in
Anglesey-related results in 2005 versus 2004 resulted primarily
from the improvement in primary aluminum market prices discussed
above. The primary aluminum market price increases were offset
by an approximate 15% contractual increase in Angleseys
power costs during the fourth quarter of 2005 as well as an
increase in major maintenance costs incurred in 2005.
Corporate and other
In 2005, corporate operating expenses consisted of
$30 million of expenses related to ongoing operations and
$5 million related to retiree medical expenses. In 2004,
corporate operating expenses consisted of $21 million of
expenses related to ongoing operations and $50 million of
retiree medical expenses.
The increase in expenses related to ongoing operations in 2005
compared to 2004 was due to an increase in professional expenses
associated primarily with our initiatives to comply with
Sarbanes-Oxley by December 31, 2006, and chapter 11
bankruptcy emergence-related activity, relocation of our
corporate headquarters and transition costs. These increased
expenses were offset by the fact that key personnel ceased
receiving retention payments as of the end of the first quarter
of 2004 pursuant to our key employee retention program. The
decline in retiree-related expenses was primarily attributable
to the termination of our Inactive Pension Plan in 2004 and the
change in retiree medical payments.
Corporate operating results for 2005, discussed above, exclude
defined contribution savings plan charges of approximately
$0.5 million.
Reorganization items
Reorganization items consist primarily of income, expenses
(including professional fees) and losses that were realized or
incurred by us due to our chapter 11 bankruptcy
reorganization. Reorganization items increased substantially in
2005 over 2004 as a result of a non-cash charge of approximately
of $1,131.5 million in the fourth quarter of 2005. The
non-cash charge was recognized in connection with the
consummation of the plans of liquidation filed by certain of our
subsidiaries pursuant to which the value associated with an
intercompany note was assigned for the benefit of certain
third-party creditors. See Note 1 to our audited
consolidated financial statements for a more complete discussion.
38
Managements discussion and analysis of financial
condition and results of operations
Discontinued operations
Discontinued operations in 2005 included the operating results
of our interests in and related to QAL for the first quarter of
2005 and the gain that resulted from the sale of such interests
on April 1, 2005. Discontinued operations in 2004 included
a full year of operating results attributable to our interests
in and related to QAL, as well as the operating results of the
commodity interests that were sold at various times during 2004.
Income from discontinued operations for 2005 increased
approximately $242 million over 2004. The primary factor
for the improved results was the larger gain on the sale of our
QAL interests (approximately $366 million) in 2005 compared
to the gains from the sale of our interests in and related to
Alumina Partners of Jamaica, or Alpart, and the sale of our Mead
facility (approximately $127 million) in 2004. The adverse
impacts in 2005 of a $42 million non-cash contract
rejection charge were largely offset by improved operating
results in 2005 associated with QAL of $12 million and the
avoidance of $33 million of net losses by other
commodity-related interests in 2004.
YEAR ENDED DECEMBER 31, 2004 COMPARED TO YEAR ENDED
DECEMBER 31, 2003
We reported a net loss of $746.8 million in 2004 compared
to a net loss of $788.3 million for 2003. Net sales in 2004
totaled $942.4 million compared to $710.2 million
in 2003.
Fabricated aluminum products
Net sales of fabricated products increased by 35% during 2004 as
compared to 2003 primarily due to a 23% increase in shipments
and a 9% increase in average realized prices. Shipments in 2004
were higher than 2003 shipments as a result of improved demand
for most of our fabricated aluminum products, especially
aluminum plate for the general engineering market as well as
extrusions and forgings for the automotive market. Demand for
our products in the Aero/ HS market was also markedly higher in
2004 than in 2003. The increase in the average realized price
reflected changes in the mix of products sold, stronger demand
and higher underlying metal prices. Extrusion prices were
thought to have recovered from the recessionary lows experienced
in 2002 and 2003 but were still below prices experienced during
peaks in the business cycle. Plate prices increased to near
peak-level pricing in response to strong near-term demand.
Segment operating results (before other operating charges, net)
for 2004 improved over 2003 primarily due to the increased
shipment and price levels noted above, improved market
conditions and improved cost performance offset, in part, by
modestly increased natural gas prices and a $12.1 million
non-cash LIFO inventory charge. Operating results for 2003
included increased energy costs, a $3.2 million non-cash
LIFO inventory charge, and higher pension-related expenses
offset, in part, by reductions in overhead and other operating
costs as a result of cost cutting initiatives. Segment operating
results for 2004 and 2003 included gains (losses) on
intercompany hedging activities with the primary aluminum
business unit totaling $8.6 million and
$(2.3) million. These amounts eliminate in consolidation.
Segment operating results for 2003, discussed above, exclude a
net gain of approximately $3.9 million from the sale of
equipment.
Primary aluminum
Third party net sales of primary aluminum increased 18% for 2004
as compared to the same period in 2003, primarily as a result of
a 20% increase in third-party average realized prices offset by
a 1% decrease in third-party shipments. The increases in the
average realized prices were primarily due to the increases in
primary aluminum market prices. Shipments in 2004 were better
than the prior year primarily due to the timing of shipments.
39
Managements discussion and analysis of financial
condition and results of operations
Segment operating results (before other operating charges, net)
for 2004 improved over 2003 primarily due to the increases in
prices and shipments discussed above. Segment operating results
for 2004 and 2003 include gains (losses) on intercompany hedging
activities with the fabricated products business unit totaling
$(8.6) million and $2.3 million. These amounts
eliminate in consolidation.
Segment operating results for 2003, discussed above, exclude a
pre-filing date claim of approximately $3.2 million related
to a restructured transmission agreement and a net gain of
approximately $9.5 million from the sale of our Tacoma,
Washington smelter.
Corporate and other
In 2004, corporate operating costs consisted of
$21.2 million of expenses related to ongoing operations and
$50 million of retiree-related expenses. In 2003, corporate
operating costs consisted of expenses related to ongoing
operations of $39 million and $35 million of
retiree-related expenses. The decline in expenses related to
ongoing operations from 2003 to 2004 was primarily attributable
to lower salary ($1 million), retention ($4 million)
and incentive compensation ($2.5 million) costs as well as
lower accruals for pension-related costs primarily as a result
of the December 2003 termination by the Pension Benefit Guaranty
Corporation, or PBGC, of our salaried employees pension plan
($2.5 million). The increase in retiree-related expenses in
2004 from 2003 reflects managements decision to allocate
to the corporate segment the excess of post-retirement medical
costs related to the fabricated products business unit and
discontinued operations for the period May 1, 2004 through
December 31, 2004 over the amount of such segments
allocated share of VEBA contributions offset, in part, by lower
pension-related accruals as a result of the December 2003
termination by the PBGC of our salaried employees pension plan.
Corporate operating results for 2004, discussed above, exclude:
(1) pension charges of $310.0 million related to
terminated pension plans whose responsibility was assumed by the
PBGC, (2) a settlement charge of $175.0 million
related to a settlement with the USW, and (3) settlement
charges of $312.5 million related to the termination of the
post-retirement medical benefit plans (all of which are included
in other operating charges, net). Corporate operating results
for 2003 exclude a pension charge of $121.2 million related
to the terminated salaried employees pension plan assumed by the
PBGC, a charge of $15.7 million related to a multi-site
environmental settlement and hearing loss claims of
$15.8 million (all of which are included in other operating
charges, net).
Discontinued operations
Discontinued operations include the operating results for
Alpart, an alumina smelter located in Gramercy, Louisiana and
associated interest in Kaiser Jamaica Bauxite Company, or
Gramercy/ KJBC, Volta Aluminum Company Limited, or Valco, QAL
and our Mead facility and gains from the sale of our interests
in and related to these interests (except for the gain on the
sale of our interests in and related to QAL which was sold in
April 2005). Results for discontinued operations for 2004
improved $636.0 million over 2003. Approximately
$460 million of such improvement resulted from three
nonrecurring items: (1) the approximate $126.6 million
gain on the sale of our interests in and related to Alpart and
the sale of our Mead facility; (2) the $368.0 million
of impairment charges in respect of our interests in and related
to commodities interests in 2003; and
(3) $33.0 million of Valco-related impairment charges
in 2004. The balance of the improvement primarily resulted from
approximately $132 million of improved operating results at
Alpart, Gramercy/ KJBC and QAL, a substantial majority of which
was related to the improvement in average realized alumina
prices.
40
Managements discussion and analysis of financial
condition and results of operations
LIQUIDITY AND CAPITAL RESOURCES
Our primary sources of liquidity are cash generated from
operating activities and borrowings under our revolving credit
facility. We believe that the cash and cash equivalents, cash
flows from operations and cash available under the revolving
credit facility will be sufficient to satisfy the anticipated
cash requirements associated with our existing operations for at
least the next 12 months. Our ability to generate
sufficient cash from our operating activities depends on our
future performance, which is subject to general economic,
political, financial, competitive and other factors beyond our
control. In addition, our future capital expenditures and other
cash requirements could be higher than we currently expect as a
result of various factors, including any expansion of our
business that we complete.
As a result of the filing of the chapter 11 bankruptcy
proceedings, claims against us for principal and accrued
interest on secured and unsecured indebtedness existing on the
respective filing dates of our company and each of our
subsidiaries were stayed while we continued business operations
as
debtors-in-possession,
subject to the control and supervision of the bankruptcy court.
These obligations were extinguished upon our emergence from
chapter 11 bankruptcy.
Operating activities
During the nine months ended September 30, 2006, fabricated
products operating activities provided $42 million of cash
compared to $67 million of cash for the nine months ended
September 30, 2005. Cash provided by fabricated products in
the nine months ended September 30, 2006 was primarily due
to improved operating results offset, in part, by increased
working capital cash requirements. The increase in 2006 working
capital cash requirements was primarily the result of the impact
of higher primary aluminum prices and increased demand for
fabricated aluminum products on inventories and accounts
receivable, which was only partially offset by increases in
accounts payable. Cash provided by fabricated products in the
nine months ended September 30, 2005 was primarily due to
improved operating results associated with improved demand for
fabricated aluminum products. Working capital change in the nine
months ended September 30, 2005 was modest. Fabricated
products cash flow excluded consideration of pension and retiree
cash payments made in respect of current and former employees of
the fabricated products facilities. Such amounts are part of the
legacy costs that we classify as a corporate cash
outflow.
Cash flows attributable to Anglesey provided $22 million
and $17 million in the nine months ended September 30,
2006 and 2005, respectively.
Corporate and other operating activities used $82 million
of cash in the nine months ended September 30, 2006 and
2005. Cash outflows for corporate and other operating activities
in the nine months ended September 30, 2006 and 2005
included:
|
|
|
$12 million and
$18 million, respectively, for medical obligations and VEBA
funding for all former and current operating units;
|
|
|
$16 million and
$30 million, respectively, for reorganization costs; and
|
|
|
$30 million and
$20 million, respectively, for general and administrative
costs.
|
Cash outflows for corporate and other operating activities for
the nine months ended September 30, 2006 also included
$25 million of payments made pursuant to our plan of
reorganization.
In the nine months ended September 30, 2006, discontinued
operation activities provided $9 million of cash compared
to $13 million in the nine months ended September 30,
2005. Cash provided by discontinued operations in the nine
months ended September 30, 2006 consisted of, as discussed
above, the proceeds from an $8 million payment from an
insurer and a $1 million refund from
41
Managements discussion and analysis of financial
condition and results of operations
commodity interests energy vendors. Cash provided in the nine
months ended September 30, 2005 resulted from favorable
operating results of QAL offset, in part, by foreign tax
payments of $10 million.
In 2005, fabricated products operating activities provided
$88 million of cash, substantially all of which was
generated from operating results. Working capital changes were
modest. In 2004, fabricated products operating activities
provided approximately $35 million of cash,
$70 million of which was generated from operating results
offset by increases in working capital of approximately
$35 million. In 2003, fabricated products operating
activities provided approximately $30 million of cash,
substantially all of which was generated from operating results.
Working capital changes were modest. The increases in cash
provided by fabricated products operating results in 2005 and
2004 were primarily due to improving demand for fabricated
aluminum products. The increase in working capital in 2004
reflected the increase in demand as well as the significant
increase in primary aluminum prices. In 2003, cost-cutting
initiatives offset reduced product prices and shipments so that
cash provided by operations approximated that in 2002. The
foregoing analysis of fabricated products cash flow excludes
consideration of pension and retiree cash payments made in
respect of current and former employees of our fabricated
products segment. Such amounts are part of the
legacy costs that we internally categorize as a
corporate cash outflow.
Cash flows attributable to our interests in and related to our
primary aluminum business provided $20 million,
$14 million and $12 million in 2005, 2004 and 2003,
respectively. The increase in cash flows between 2005 and 2004
was primarily attributable to increases in primary aluminum
market prices. Higher primary aluminum prices in 2004 caused the
cash flows attributable to sales of primary aluminum production
from Anglesey to be approximately $2 million higher in 2004
than in 2003. The balance of the differences in cash flows
between 2004 and 2003 was primarily attributable to timing of
shipments, payments and receipts.
Corporate and other operating activities utilized
$108 million, $150 million and $100 million of
cash in 2005, 2004 and 2003, respectively. Cash outflows from
corporate and other operating activities in 2005, 2004 and 2003
included: (1) $37 million, $57 million and
$60 million, respectively, in respect of retiree medical
obligations and VEBA funding for former and current operating
units; (2) payments for reorganization costs of
$39 million, $35 million and $27 million,
respectively; and (3) payments in respect of general and
administrative costs totaling approximately $29 million,
$26 million and $27 million, respectively. Corporate
operating cash flow in 2003 included asbestos-related insurance
receipts of approximately $18 million. Cash outflows in
2004 also included $27 million to settle certain multi-site
environmental claims.
In 2005, discontinued operation activities provided
$17 million of cash. This compares with 2004 and 2003 when
discontinued operation activities provided $64 million and
used $29 million of cash, respectively. The decrease in
cash provided by discontinued operations in 2005 over 2004
resulted primarily from a decrease in favorable operating
results due to the sale of substantially all of our commodity
interests between the second half of 2004 and early 2005. The
remaining commodity interests were sold as of April 1,
2005. The increase in cash provided by discontinued operations
in 2004 over 2003 resulted from improved operating results due
primarily to the improvement in average realized alumina prices.
Investing activities
Total capital expenditures for our fabricated products business
were $38.7 million and $20.1 million for the nine
months ended September 30, 2006 and 2005, respectively. As
previously disclosed, we currently expect total capital
expenditures for our fabricated products business in 2006 to be
in the $65 million to $75 million range. Total capital
expenditures for our fabricated products business are
42
Managements discussion and analysis of financial
condition and results of operations
currently expected to be in the $60 million to
$70 million range for 2007. The higher level of capital
spending primarily reflects incremental investments,
particularly at our Trentwood facility. We initially announced a
$75 million expansion project of our Trentwood facility
and, in August 2006, announced a follow-on investment of an
additional $30 million. These investments are being made
primarily for new equipment and furnaces that will enable us to
supply heavy gauge, heat treat stretched plate to the aerospace
and general engineering markets and will provide incremental
capacity. Since the inception of the project during 2005,
approximately $45 million has been incurred as of
September 30, 2006. Besides the Trentwood facility
expansion, our remaining capital spending in 2006 was, and in
2007 will be, spread among all manufacturing locations. A
majority of the remaining capital spending is expected to reduce
operating costs, improve product quality or increase capacity.
However, we have not committed to any individual projects of
significant size, other than the Trentwood expansion, at this
time.
Total capital expenditures for fabricated products were
$30.6 million, $7.6 million, and $8.9 million in
2005, 2004 and 2003, respectively. The capital expenditures were
made primarily to improve production efficiency, reduce
operating costs and expand capacity at existing facilities.
Total capital expenditures for discontinued operations were
$3.5 million and $28.3 million in 2004 and 2003,
respectively (of which $1.0 million and $8.9 million,
respectively, were funded by the minority partners in certain
foreign joint ventures).
Our level of capital expenditures may be adjusted from time to
time depending on our business plans, price outlook for metal
and other products, our ability to maintain adequate liquidity
and other factors. If our sales growth continues and the
relevant market factors remain positive, we may increase our
capital spending in 2007 from the amounts described above, and
if our sales decline or the market factors do not remain
positive, our capital spending may be decreased from the amounts
described above.
Depending upon conditions in the capital markets and other
factors, we will from time to time consider the issuance of debt
or equity securities, or other possible capital markets
transactions, the proceeds of which could be used to refinance
current indebtedness or for other corporate purposes. Pursuant
to our growth strategy, we will also consider from time to time
acquisitions of, and investments in, assets or businesses that
complement our existing assets and businesses. Acquisition
transactions, if any, are expected to be financed through cash
on hand and from operations, bank borrowings, the issuance of
debt or equity securities or a combination of two or more of
those sources.
Financing facilities
After emergence from chapter 11 bankruptcy
On July 6, 2006, we entered into a $200.0 million
revolving credit facility with a group of lenders, of which up
to a maximum of $60.0 million may be utilized for letters
of credit. Under the revolving credit facility, we may borrow
(or obtain letters of credit) from time to time in an aggregate
amount equal to the lesser of $200.0 million and a
borrowing base comprised of eligible accounts receivable,
eligible inventory and certain eligible machinery, equipment and
real estate, reduced by certain reserves, all as specified in
the revolving credit facility. The revolving credit facility has
a five-year term and matures in July 2011, at which time all
principal amounts outstanding thereunder will be due and
payable. Borrowings under the revolving credit facility bear
interest at a rate equal to either a base prime rate or LIBOR,
at our option, plus a specified variable percentage determined
by reference to the then remaining borrowing availability under
the revolving credit facility. The revolving credit facility
may, subject to certain conditions and the agreement of lenders
thereunder, be increased up to $275.0 million.
43
Managements discussion and analysis of financial
condition and results of operations
Concurrently with the execution of the revolving credit
facility, we also entered into a term loan facility that
provides for a $50.0 million term loan and is guaranteed by
certain of our domestic operating subsidiaries. The term loan
facility was fully drawn on August 4, 2006. The term loan
facility has a five-year term and matures in July 2011, at which
time all principal amounts outstanding thereunder will be due
and payable. Borrowings under the term loan facility bear
interest at a rate equal to either a premium over a base prime
rate or LIBOR, at our option.
Amounts owed under each of the revolving credit facility and the
term loan facility may be accelerated upon the occurrence of
various events of default set forth in each agreement, including
the failure to make principal or interest payments when due, and
breaches of covenants, representations and warranties set forth
in each agreement.
The revolving credit facility is secured by a first priority
lien on substantially all of our assets and the assets of our
domestic operating subsidiaries that are also borrowers
thereunder. The term loan facility is secured by a second lien
on substantially all of our assets and the assets of our
domestic operating subsidiaries that are the borrowers or
guarantors thereof.
Both credit facilities place restrictions on our ability to,
among other things, incur debt, create liens, make investments,
pay dividends, repurchase our common stock, sell assets,
undertake transactions with affiliates and enter into unrelated
lines of business.
During July 2006, we borrowed and repaid $8.6 million under
the revolving credit facility. At October 31, 2006, there
were no borrowings outstanding under the revolving credit
facility, there was approximately $15.9 million outstanding
under letters of credit and there was $50.0 million
outstanding under the term loan facility.
Prior to emergence from chapter 11 bankruptcy
On February 11, 2005, we entered into a new financing
agreement with a group of lenders under which we were provided
with a replacement for the existing post-petition credit
facility and a commitment for a multi-year exit financing
arrangement upon our emergence from our chapter 11
bankruptcy proceedings. The financing agreement was replaced by
our revolving credit facility and term loan on July 6,
2006, the effective date of our plan of reorganization.
CONTRACTUAL OBLIGATIONS AND COMMERCIAL COMMITMENTS
The following summarizes our significant contractual obligations
at September 30, 2006 (dollars in millions):
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|
|
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Payments due in | |
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| |
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Less than | |
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2-3 | |
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4-5 | |
|
More than | |
Contractual obligations |
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Total | |
|
1 year | |
|
years | |
|
years | |
|
5 years | |
| |
Long-term debt
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$ |
50.0 |
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|
$ |
|
|
|
$ |
|
|
|
$ |
50.0 |
|
|
$ |
|
|
Operating leases
|
|
|
7.4 |
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|
|
2.6 |
|
|
|
3.1 |
|
|
|
1.6 |
|
|
|
0.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total cash contractual
obligations(1)
|
|
$ |
57.4 |
|
|
$ |
2.6 |
|
|
$ |
3.1 |
|
|
$ |
51.6 |
|
|
$ |
0.1 |
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|
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(1) |
Total contractual obligations exclude future annual variable
cash contributions to the VEBAs, which cannot be determined at
this time. See Off Balance Sheet and Other
Arrangements below for a summary of possible annual
variable cash contribution amounts at various levels of earnings
and cash expenditures. |
44
Managements discussion and analysis of financial
condition and results of operations
OFF BALANCE SHEET AND OTHER ARRANGEMENTS
As of September 30, 2006, outstanding letters of credit
under our revolving credit facility were approximately
$17.7 million, substantially all of which expire within
approximately twelve months. The letters of credit relate
primarily to insurance, environmental and other activities.
We have agreements to supply alumina to and purchase aluminum
from Anglesey. Both the alumina sales agreement and primary
aluminum purchase agreement are tied to primary aluminum prices.
The following employee benefit plans remain in effect:
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A commitment to provide one or
more defined contribution 401(k) plans as a replacement for
three of four defined benefit pension plans for hourly
bargaining unit employees at four of our production facilities.
The defined benefit plans at these four production facilities
were terminated during the fourth quarter of 2006, effective as
of October 10, 2006, pursuant to a court ruling received in
July 2006. These replacement plans provide for an annual
contribution ranging from $800 to $2,400 per bargaining unit
employee, depending on the employees age. We also agreed
to make monthly contributions of one dollar per hour worked by
each bargaining unit employee to the appropriate multi-employer
pension plans sponsored by the USW and certain other unions at
each of these four facilities.
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A defined contribution 401(k)
savings plan for hourly bargaining unit employees at all of our
other production facilities. Pursuant to the terms of the
defined contribution plan, we will be required to make annual
contributions to the Steelworkers Pension Trust on the basis of
one dollar per USW employee hour worked at two facilities.
We will also be required to make contributions to the defined
contribution savings plan for active USW employees at these
facilities that will range from $800 to $2,400 per employee
per year, depending on the employees age.
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A defined benefit pension plan
for our salaried employees at our facility in London, Ontario
with annual contributions based on each salaried employees
age and years of service.
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A defined contribution savings
plan for salaried and non-bargaining unit hourly employees
providing for a match of certain contributions made by employees
plus a contribution of between 2% and 10% of their salary
depending on their age and years of service.
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A defined benefit pension plan
for one inactive operation with three remaining former employees
covered by that plan.
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An annual variable cash
contribution to the VEBAs. The amount to be contributed to the
VEBAs will be 10% of the first $20.0 million of annual cash
flow (defined generally as earnings before interest expense,
provision for income taxes and depreciation and amortization
(EBITDA) less cash payments for, among other things,
interest, income taxes and capital expenditures (Cash
Payments)) plus 20% of annual cash flow, as defined, in
excess of $20.0 million. Such annual payments will not
exceed $20.0 million and will also be limited (with no
carryover to future years) to the extent that the payments would
cause our liquidity to be less than $50.0 million. Such
amounts will be determined on an annual basis and payable no
later than March 31 of the following year. However, we have
the ability to offset amounts that would otherwise be due to the
VEBAs with approximately $12.7 million of excess
contributions made to the VEBAs prior to the effective date of
our plan of reorganization.
|
45
Managements discussion and analysis of financial
condition and results of operations
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The following table shows (in millions of dollars) the estimated
amount of variable VEBA payments that would occur at differing
levels of EBITDA and Cash Payments in respect of, among other
items, interest, income taxes and capital expenditures. The
table below does not consider the liquidity limitation, the
$12.7 million of advances available to us to offset VEBA
obligations as they become due and certain other factors that
could effect the amount of variable VEBA payments due and,
therefore, should be considered only for illustrative purposes. |
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Cash Payments | |
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| |
EBITDA |
|
$25.0 | |
|
$50.0 | |
|
$75.0 | |
|
$100.0 | |
| |
$ 20.0
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
40.0
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|
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1.5 |
|
|
|
|
|
|
|
|
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60.0
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|
|
5.0 |
|
|
|
1.0 |
|
|
|
|
|
|
|
|
|
80.0
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|
|
9.0 |
|
|
|
4.0 |
|
|
|
0.5 |
|
|
|
|
|
100.0
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|
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13.0 |
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8.0 |
|
|
|
3.0 |
|
|
|
|
|
120.0
|
|
|
17.0 |
|
|
|
12.0 |
|
|
|
7.0 |
|
|
|
2.0 |
|
140.0
|
|
|
20.0 |
|
|
|
16.0 |
|
|
|
11.0 |
|
|
|
6.0 |
|
160.0
|
|
|
20.0 |
|
|
|
20.0 |
|
|
|
15.0 |
|
|
|
10.0 |
|
180.0
|
|
|
20.0 |
|
|
|
20.0 |
|
|
|
19.0 |
|
|
|
14.0 |
|
200.0
|
|
|
20.0 |
|
|
|
20.0 |
|
|
|
20.0 |
|
|
|
18.0 |
|
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A short-term incentive plan for
management, payable in cash, which is based primarily on
earnings, adjusted for certain safety and performance factors.
Most of our locations have similar programs for both hourly and
salaried employees.
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A stock based long-term
incentive plan for key managers. As more fully discussed in
Note 7 to our interim consolidated financial statements an
initial, emergence-related award was made under this program.
Additional awards are expected to be made in future years.
|
In connection with the sale of our interests in and related to
Gramercy/ KJBC, we agreed to indemnify the buyers for up to
$5 million of losses suffered by the buyers that result
from any failure of our representations and warranties to be
true. Upon the closing of the transaction, such amount was
recorded in long-term liabilities in the accompanying financial
statements. A claim for the full amount of the indemnity was
made initially. However, in October 2006, the claimant filed a
revised report to indicate that its claim was approximately
$2 million and separately filed for summary judgment in
respect to its claim. We continue to evaluate the claim and, as
such, have no basis nor enough information to revise the
accrual. The indemnity expired with respect to additional claims
in October 2006.
During the third quarter of 2005 and August 2006, we placed
orders for certain equipment and services intended to augment
our heat treat and aerospace capabilities at our Trentwood
facility. We expect to become obligated for costs related to
these orders of approximately $105 million, of which
approximately $45 million of such cost was incurred in 2005
and through the third quarter of 2006. The majority of the
balance will likely be incurred primarily over the remainder of
2007.
At September 30, 2006, there was approximately
$7.1 million of accrued, but unpaid professional fees that
have been approved for payment by the bankruptcy court.
Additionally, certain professionals had success fees
due upon our emergence from chapter 11 bankruptcy.
Approximately $5.0 million of such amounts were recorded in
connection with our emergence from chapter 11 bankruptcy
and the implementation of fresh start reporting and paid by us
after September 30, 2006.
46
Managements discussion and analysis of financial
condition and results of operations
NEW ACCOUNTING PRONOUNCEMENTS
Please see Note 2 to our interim consolidated financial
statements for a discussion of new accounting pronouncements.
Statement of Financial Accounting Standards No. 158,
Employers Accounting for Defined Benefit Pension and
Other Postretirement Plans, an amendment of FASB Statements
No. 87, 88, 106, and 132(R), SFAS No. 158,
was issued in September 2006. SFAS No. 158 requires a
company to recognize the overfunded or underfunded status of
single-employer defined benefit postretirement plan(s) as an
asset or liability in its statement of financial position and to
recognize changes in that funded status in comprehensive income
in the year in which the changes occur. Prior standards only
required the overfunded or underfunded status of a plan to be
disclosed in the notes to the financial statements. In addition,
SFAS No. 158 requires that a company disclose in the
notes to the financial statements additional information about
certain effects on net periodic benefit cost for the next fiscal
year that arise from delayed recognition of the gains or losses,
prior service costs or credits and transition assets or
obligations. We must adopt SFAS No. 158 in our 2006
annual financial statements. Given the application of fresh
start reporting in the third quarter of 2006, the funded status
of our defined benefit pension plans is fully reflected in our
September 30, 2006 balance sheet and therefore we expect
SFAS No. 158 to have no material impact on our balance
sheet reporting for these plans. However, we have not yet
completed our review of the possible impacts of
SFAS No. 158 in respect of the net assets or
obligations of the Salaried Retiree VEBA Trust and the Union
VEBA Trust and cannot, therefore, predict what, if any, impacts
adoption of SFAS No. 158 will have on the balance
sheet in regard to the VEBAs.
Statement of Financial Accounting Standards No. 157,
Fair Value Measurements, SFAS No. 157, was
issued in September 2006 to increase consistency and
comparability in fair value measurements and to expand related
disclosures. The new standard includes a definition of fair
value as well as a framework for measuring fair value. The
provisions of this standard apply to other accounting
pronouncements that require or permit fair value measurements.
The standard is effective for fiscal periods beginning after
November 15, 2007 and should be applied prospectively,
except for certain financial instruments where it must be
applied retrospectively as a cumulative-effect adjustment to the
balance of opening retained earnings in the year of adoption. We
are still evaluating SFAS No. 157 but do not currently
anticipate that the adoption of this standard will have a
material impact on our financial statements.
Staff Accounting Bulletin No. 108, Guidance for
Quantifying Financial Statement Misstatements,
SAB No. 108, was issued by the SEC staff in September
2006. SAB No. 108 establishes a specific approach for
the quantification of financial statement errors based on the
effects of the error on each of our financial statements and the
related financial statement disclosures. The provisions of
SAB No. 108 are effective for our 2006 annual
financial statements. We do not anticipate that the adoption of
this bulletin will have a material impact on its financial
statements.
CRITICAL ACCOUNTING POLICIES
Successor
Critical accounting policies fall into two broad categories. The
first type of critical accounting policies includes those that
are relatively straightforward in their application, but which
can have a significant impact on the reported balances and
operating results, like revenue recognition policies and
inventory accounting methods. The first type of critical
accounting policies is outlined in Note 2 of our interim
consolidated financial statements and is not addressed below.
The second type of critical accounting policies includes those
that are both very important to the portrayal of our financial
condition and results and require managements most
difficult, subjective and/or complex judgments. Typically, the
circumstances that make these judgments difficult, subjective
and/or complex have to do with the need
47
Managements discussion and analysis of financial
condition and results of operations
to make estimates about the effect of matters that are
inherently uncertain. Our critical accounting policies after
emergence from chapter 11 bankruptcy will, in some cases,
be different from those before emergence, as many of the
significant judgments affecting the financial statements related
to matters or items directly a result of the chapter 11
bankruptcy or related to liabilities that were resolved pursuant
to our plan of reorganization. See the Notes to our interim
consolidated financial statements for discussion of possible
differences.
While we believe that all aspects of our financial statements
should be studied and understood in assessing our current and
expected future financial condition and results, we believe that
the accounting policies that warrant additional attention
include:
Application of fresh start reporting
Upon our emergence from chapter 11 bankruptcy, we applied
fresh start reporting to our consolidated financial statements
as required by
SOP 90-7. As such,
in July 2006, we adjusted stockholders equity to equal the
reorganization value of the entity at emergence. Additionally,
items such as accumulated depreciation, accumulated deficit and
accumulated other comprehensive income (loss) were reset to
zero. We allocated the reorganization value to our individual
assets and liabilities based on their estimated fair value at
the emergence date based, in part, on information from a
third-party appraiser. Such items as current liabilities,
accounts receivable and cash reflected values similar to those
reported prior to emergence. Items such as inventory, property,
plant and equipment, long-term assets and long-term liabilities
were significantly adjusted from amounts previously reported.
Because fresh start reporting was adopted at emergence and
because of the significance of liabilities subject to compromise
that were relieved upon emergence, meaningful comparisons
between the historical financial statements and the financial
statements from and after emergence are difficult to make.
Our judgments and estimates with respect to commitments and
contingencies
Valuation of legal and other contingent claims is subject to a
great deal of judgment and substantial uncertainty. Under
U.S. generally accepted accounting principles, or GAAP,
companies are required to accrue for contingent matters in their
financial statements only if the amount of any potential loss is
both probable and the amount (or a range) of
possible loss is estimatable. In reaching a
determination of the probability of an adverse ruling in respect
of a matter, we typically consult outside experts. However, any
such judgments reached regarding probability are subject to
significant uncertainty. We may, in fact, obtain an adverse
ruling in a matter that we did not consider a
probable loss and which, therefore, was not accrued
for in our financial statements. Additionally, facts and
circumstances in respect of a matter can change causing key
assumptions that were used in previous assessments of a matter
to change. It is possible that amounts at risk in respect of one
matter may be traded off against amounts under
negotiations in a separate matter. Further, in estimating the
amount of any loss, in many instances a single estimation of the
loss may not be possible. Rather, we may only be able to
estimate a range for possible losses. In such event, GAAP
requires that a liability be established for at least the
minimum end of the range assuming that there is no other amount
which is more likely to occur.
Our judgments and estimates in respect of our employee
defined benefit plans
Defined benefit pension and post-retirement medical obligations
included in the consolidated financial statements at
June 30, 2006 and at prior dates are based on assumptions
that were subject to variation from year to year. Such
variations could have caused our estimate of such obligations to
vary significantly. Restructuring actions relating to our exit
from most of our commodities businesses (such as the indefinite
curtailment of the Mead smelter) also had a significant impact
on such amounts.
The most significant assumptions used in determining the
estimated year-end obligations were the assumed discount rate,
long-term rate of return, or LTRR, and the assumptions regarding
future
48
Managements discussion and analysis of financial
condition and results of operations
medical cost increases. Since recorded obligations represent the
present value of expected pension and post-retirement benefit
payments over the life of the plans, decreases in the discount
rate (used to compute the present value of the payments) would
cause the estimated obligations to increase. Conversely, an
increase in the discount rate would cause the estimated present
value of the obligations to decline. The LTRR on plan assets
reflects an assumption regarding what the amount of earnings
would be on existing plan assets (before considering any future
contributions to the plans). Increases in the assumed LTRR would
cause the projected value of plan assets available to satisfy
pension and post-retirement obligations to increase, yielding a
reduced net expense in respect of these obligations. A reduction
in the LTRR would reduce the amount of projected net assets
available to satisfy pension and post-retirement obligations
and, thus, cause the net expense in respect of these obligations
to increase. As the assumed rate of increase in medical costs
goes up, so does the net projected obligation. Conversely, if
the rate of increase was assumed to be smaller, the projected
obligation declines.
Our judgments and estimates in respect to environmental
commitments and contingencies
We are subject to a number of environmental laws and
regulations, to fines or penalties assessed for alleged breaches
of such laws and regulations and to claims and litigation based
upon such laws and regulations. Based on our evaluation of
environmental matters, we have established environmental
accruals, primarily related to potential solid waste disposal
and soil and groundwater remediation matters. These
environmental accruals represent our estimate of costs
reasonably expected to be incurred on a going concern basis in
the ordinary course of business based on presently enacted laws
and regulations, currently available facts, existing technology
and our assessment of the likely remediation action to be taken.
However, making estimates of possible environmental remediation
costs is subject to inherent uncertainties. As additional facts
are developed and definitive remediation plans and necessary
regulatory approvals for implementation of remediation are
established or alternative technologies are developed, changes
in these and other factors may result in actual costs exceeding
the current environmental accruals.
See Note 8 of our notes to interim consolidated financial
statements for additional information in respect of
environmental contingencies.
Our judgments and estimates in respect of conditional asset
retirement obligations
Companies are required to estimate incremental costs for special
handling, removal and disposal costs of materials that may or
will give rise to conditional asset retirement obligations and
then discount the expected costs back to the current year using
a credit adjusted risk free rate. Under current accounting
guidelines, liabilities and costs for conditional asset
retirement obligations must be recognized in a companys
financial statements even if it is unclear when or if the
conditional asset retirement obligations will be triggered. If
it is unclear when or if a conditional asset retirement
obligation will be triggered, companies are required to use
probability weighting for possible timing scenarios to determine
the probability weighted amounts that should be recognized in
our financial statements. We have evaluated our exposures to
conditional asset retirement obligations and determined that we
have conditional asset retirement obligations at several of our
facilities. The vast majority of such conditional asset
retirement obligations consist of incremental costs that would
be associated with the removal and disposal of asbestos (all of
which is believed to be fully contained and encapsulated within
walls, floors, ceilings or piping) at certain of the older
facilities if such facilities were to undergo major renovation
or be demolished. No plans currently exist for any such
renovation or demolition of such facilities and our current
assessment is that the most probable scenarios are that no such
conditional asset retirement obligation would be triggered for
20 or more years, if at all. Nonetheless, we have recorded an
estimated conditional asset retirement obligation liability of
approximately $2.7 million at December 31, 2005 and we
expect that this amount will increase substantially over time.
49
Managements discussion and analysis of financial
condition and results of operations
The estimation of conditional asset retirement obligations is
subject to a number of inherent uncertainties including:
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the timing of when any such
conditional asset retirement obligation may be incurred;
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the ability to accurately
identify all materials that may require special handling or
treatment;
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the ability to reasonably
estimate the total incremental special handling and other costs;
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the ability to assess the
relative probability of different scenarios which could give
rise to a conditional asset retirement obligation; and
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other factors outside our
control including changes in regulations, costs and interest
rates.
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Actual costs and the timing of such costs may vary significantly
from the estimates, judgments and probable scenarios we
considered, which could, in turn, have a material impact on our
future financial statements.
Recoverability of recorded asset values
Under GAAP, assets to be held and used are evaluated for
recoverability differently than assets to be sold or disposed
of. Assets to be held and used are evaluated based on their
expected undiscounted future net cash flows. So long as we
reasonably expect that such undiscounted future net cash flows
for each asset will exceed the recorded value of the asset being
evaluated, no impairment is required. However, if plans to sell
or dispose of an asset or group of assets meet a number of
specific criteria, then, under GAAP, such assets should be
considered held for sale/disposition and their recoverability
should be evaluated, based on expected consideration to be
received upon disposition. Sales or dispositions at a particular
time will be affected by, among other things, the existing
industry and general economic circumstances as well as our own
circumstances, including whether or not assets will (or must) be
sold on an accelerated or more extended timetable. Such
circumstances may cause the expected value in a sale or
disposition scenario to differ materially from the realizable
value over the normal operating life of assets, which would
likely be evaluated on long-term industry trends.
Income Tax Provisions in Interim Periods
In accordance with GAAP, financial statements for interim
periods are to include an income tax provision based on the
effective tax rate expected to be incurred in the current year.
Accordingly, estimates and judgments must be made for each
applicable taxable jurisdiction as to the amount of taxable
income that may be generated, the availability of deductions and
credits expected and the availability of net operating loss
carry-forwards or other tax attributes to offset taxable income.
Making such estimates and judgments is subject to inherent
uncertainties given the difficulty of predicting such factors as
future market conditions, customer requirements, the cost for
key inputs such as energy and primary aluminum, its overall
operating efficiency and many other items. For purposes of
preparing our September 30, 2006 interim consolidated
financial statements, we have considered our actual operating
results in the nine months ended September 30, 2006 as well
as our forecasts for the balance of the year. Based on this and
other available information, we do not expect to generate
U.S. taxable income for the full year. However, if, among
other things:
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actual results for the balance
of 2006 vary from that in the nine months ended
September 30, 2006 and our forecasts due to one or more of
the factors cited above or elsewhere in this prospectus;
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income is distributed
differently than expected among tax jurisdictions;
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one or more material events or
transactions occur which were not contemplated; or
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certain expected deductions,
credits or carryforwards are not available;
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50
Managements discussion and analysis of financial
condition and results of operations
then, it is possible that the effective tax rate for 2006 could
vary materially from the assessments used to prepare the
September 30, 2006 interim consolidated financial
statements included elsewhere in this prospectus. Additionally,
following emergence from chapter 11 bankruptcy, our tax
provision will be affected by the impacts of our plan of
reorganization and by the application of fresh start reporting.
Predecessor
As indicated above, critical accounting policies are those that
are both very important to the portrayal of our financial
condition and results and require managements most
difficult, subjective and/or complex judgments. Typically, the
circumstances that make these judgments difficult, subjective
and/or complex have to do with the need to make estimates about
the effect of matters that are inherently uncertain. Our
critical accounting policies after emergence from
chapter 11 bankruptcy will, in some cases, be different
from those before emergence. Many of the significant judgments
affecting our financial statements relate to matters related to
our chapter 11 bankruptcy or liabilities that were resolved
pursuant to our plan of reorganization.
While we believe all aspects of our financial statements should
be studied and understood in assessing our current and future
financial condition and results, we believe that the accounting
policies that warrant additional attention include:
Our judgments and estimates with respect to commitments and
contingencies
Valuation of legal and other contingent claims is subject to
judgment and substantial uncertainty. Under GAAP companies are
required to accrue for contingent matters in their financial
statements only if the amount of any potential loss is both
probable and the amount or range of possible loss is
estimatable. In reaching a determination of the
probability of an adverse rulings, we typically consult outside
experts. However, any judgments reached regarding probability
are subject to significant uncertainty. We may, in fact, obtain
an adverse ruling in a matter that we did not consider a
probable loss and which was not accrued for in our
financial statements. Additionally, facts and circumstances
causing key assumptions that were used in previous assessments
are subject to change. It is possible that amounts at risk in
one matter may be traded off against amounts
under negotiation in a separate matter. Further, in many
instances a single estimation of a loss may not be possible.
Rather, we may only be able to estimate a range for possible
losses. In such event, GAAP requires that a liability be
established for at least the minimum end of the range assuming
that there is no other amount which is more likely to occur.
Prior to our emergence from chapter 11 bankruptcy, we had
two potentially material contingent obligations that were
subject to significant uncertainty and variability in their
outcome: (1) the USW unfair labor practice claim and
(2) the net obligation in respect of personal
injury-related matters. See Business Legal
Proceedings.
As more fully discussed in Note 19 of our interim
consolidated financial statements, we accrued an amount in the
fourth quarter of 2004 for the USW unfair labor practice
matter. We did not accrue any amount prior to the fourth quarter
of 2004 because we did not consider the loss to be
probable. Our assessment had been that the possible
range of loss in this matter ranged from zero to
$250.0 million based on the proof of claims filed (and
other information provided) by the National Labor Relations
Board, or NLRB, and the USW in connection with our
chapter 11 bankruptcy proceedings. While we continued to
believe that the unfair labor practice charges were without
merit, during January 2004, we agreed to allow a claim in favor
of the USW in the amount of the $175.0 million as a
compromise and in return for the USW agreeing to substantially
reduce or eliminate certain benefit payments as more fully
discussed in Note 19 to our interim consolidated financial
statements. However, this settlement was not recorded at that
time because it was still subject to bankruptcy court approval.
The settlement was ultimately approved by the bankruptcy court in
51
Managements discussion and analysis of financial
condition and results of operations
February 2005 and, as a result of the contingency being removed
with respect to this item (which arose prior to the
December 31, 2004 balance sheet date), a
non-cash charge of
$175.0 million was reflected in our consolidated financial
statements at December 31, 2004.
Also, as more fully discussed in Note 19 to our interim
consolidated financial statements, we were one of many
defendants in personal injury claims by a large number of
persons who asserted that their injuries were caused by, among
other things, exposure to asbestos during, or as a result of,
their employment or association with us or by exposure to
products containing asbestos last produced or sold by us more
than 20 years ago. We have also previously disclosed that
certain other personal injury claims had been filed in respect
of alleged pre-filing date exposure to silica and coal tar pitch
volatiles. Due to the chapter 11 bankruptcy proceedings,
existing lawsuits in respect of all such personal injury claims
were stayed and new lawsuits could not be commenced against us.
Our June 30, 2006 balance sheet includes a liability for
estimated asbestos-related costs of $1,115 million, which
represented our estimate of the minimum end of a range of costs.
The upper end of our estimate of costs was approximately
$2,400 million and we were aware that certain constituents
had asserted that they believed that actual costs could exceed
the top end of our estimated range, by a potentially material
amount. No estimation of our liabilities in respect of such
matters occurred as a part of our plan of reorganization.
However, given that our plan of reorganization was implemented
in July 2006, all such obligations in respect of personal injury
claims have been resolved and will not have a continuing effect
on our financial condition after emergence.
Our June 30, 2006 balance sheet includes a long-term
receivable of $963.3 million for estimated insurance
recoveries in respect of personal injury claims. We believed
that, prior to the implementation of our plan of reorganization,
recovery of this amount was probable (if our plan of
reorganization was not approved) and additional amounts were
recoverable in the future if additional liability were
ultimately determined to exist. However, we could not provide
assurance that all such amounts would be collected. However, as
our plan of reorganization was implemented in July 2006, the
rights to the proceeds from these policies have been transferred
(along with the applicable liabilities) to certain personal
injury trusts set up as a part of our plan of reorganization and
we have no continuing interests in such policies.
Our judgments and estimates related to employee benefit
plans
Pension and post-retirement medical obligations included in the
consolidated balance sheet at June 30, 2006 and at prior
dates were based on assumptions that were subject to variation
from year to year. Such variations can cause our estimate of
such obligations to vary significantly. Restructuring actions
relating to our exit from most of our commodities businesses
also had a significant impact on the amount of these obligations.
For pension obligations, the most significant assumptions used
in determining the estimated
year-end obligation are
the assumed discount rate and LTRR on pension assets. Since
recorded pension obligations represent the present value of
expected pension payments over the life of the plans, decreases
in the discount rate used to compute the present value of the
payments would cause the estimated obligations to increase.
Conversely, an increase in the discount rate would cause the
estimated present value of the obligations to decline. The LTRR
on pension assets reflects our assumption regarding what the
amount of earnings would be on existing plan assets before
considering any future contributions to the plans. Increases in
the assumed LTRR would cause the projected value of plan assets
available to satisfy pension obligations to increase, yielding a
reduced net pension obligation. A reduction in the LTRR would
reduce the amount of projected net assets available to satisfy
pension obligations and, thus, caused the net pension obligation
to increase.
For post-retirement obligations, the key assumptions used to
estimate the year-end
obligations were the discount rate and the assumptions regarding
future medical costs increases. The discount rate affected
52
Managements discussion and analysis of financial
condition and results of operations
the post-retirement obligations in a similar fashion to that
described above for pension obligations. As the assumed rate of
increase in medical costs went up, so did the net projected
obligation. Conversely, as the rate of increase was assumed to
be smaller, the projected obligation declined.
Since our largest pension plans and the post-retirement medical
plans were terminated in 2003 and 2004, the amount of
variability in respect of such plans was substantially reduced.
However, there were five remaining defined benefit pension plans
that were still ongoing pending the resolution of certain
litigation with the PBGC. We prevailed in the litigation against
the PBGC in August 2006. Accordingly, four of the five remaining
plans were terminated during the fourth quarter of 2006,
effective as of October 10, 2006, and were replaced by defined
contribution 401(k) plans and contributions to related
multi-employer pension plans maintained by the USW and certain
other unions.
Given that all of our significant benefit plans after the
emergence date are defined contribution plans or have limits on
the amounts to be paid, our future financial statements will not
be subject to the same volatility as our financial statements
prior to emergence and the termination of the plans.
Our judgments and estimates related to environmental
commitments and contingencies
We are subject to a number of environmental laws and
regulations, to fines or penalties that may be assessed for
alleged breaches of such laws and regulations and to clean-up
obligations and other claims and litigation based upon such laws
and regulations. We have in the past been and may in the future
be subject to a number of claims under the Comprehensive
Environmental Response, Compensation and Liability Act of 1980,
as amended by the Superfund Amendments Reauthorization Act of
1986, or CERCLA.
Based on our evaluation of these and other environmental
matters, we have established environmental accruals, primarily
related to investigations and potential remediation of the soil,
groundwater and at our current operating facilities that may
have been adversely impacted by hazardous materials, including
polychlorinated biphenyls, or PCBs. These environmental accruals
represent our estimate of costs reasonably expected to be
incurred on a going concern basis in the ordinary course of
business based on presently enacted laws and regulations,
currently available facts, existing technology and our
assessment of the likely remedial action to be taken. However,
making estimates of possible environmental costs is subject to
inherent uncertainties. As additional facts are developed and
definitive remediation plans and necessary regulatory approvals
for implementation of remediation are established or alternative
technologies are developed, actual costs may exceed the current
environmental accruals.
Our judgments and estimates related to conditional asset
retirement obligations
Companies are required to estimate incremental costs for special
handling, removal and disposal costs of materials that may or
will give rise to conditional asset retirement obligations and
then discount the expected costs back to the current year using
a credit adjusted risk free rate. Under current accounting
guidelines, liabilities and costs for conditional asset
retirement obligations must be recognized in a companys
financial statements even if it is unclear when or if the
conditional asset retirement obligations will be triggered. If
it is unclear when or if a conditional asset retirement
obligation will be triggered, companies are required to use
probability weighting for possible timing scenarios to determine
the probability weighted amounts that should be recognized in
our financial statements. We have evaluated our exposures to
conditional asset retirement obligations and determined that we
have conditional asset retirement obligations at several of our
facilities. The vast majority of such conditional asset
retirement obligations consist of incremental costs that would
be associated with the removal and disposal of asbestos (all of
which is believed to be fully contained and encapsulated within
walls, floors, ceilings or piping) at certain of the older
facilities if such facilities were to undergo major renovation
or be demolished. No plans currently exist for any such
renovation or demolition of
53
Managements discussion and analysis of financial
condition and results of operations
such facilities and our current assessment is that the most
probable scenarios are that no such conditional asset retirement
obligation would be triggered for 20 or more years, if at all.
Nonetheless, we recorded an estimated conditional asset
retirement obligation liability of approximately
$2.7 million at December 31, 2005 and we expect that
this amount will increase substantially over time.
The estimation of conditional asset retirement obligations is
subject to a number of inherent uncertainties including:
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the timing of when any such
conditional asset retirement obligation may be incurred;
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the ability to accurately
identify all materials that may require special handling or
treatment;
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the ability to reasonably
estimate the total incremental special handling and other costs;
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the ability to assess the
relative probability of different scenarios which could give
rise to a conditional asset retirement obligation; and
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other factors outside our
control including changes in regulations, costs and interest
rates.
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Actual costs and the timing of such costs may vary significantly
from the estimates, judgments and probable scenarios we
considered, which could, in turn, have a material impact on our
future financial statements.
Recoverability of recorded asset values
Under GAAP, assets to be held and used are evaluated for
recoverability differently than assets to be sold or disposed
of. Assets to be held and used are evaluated based on their
expected undiscounted future net cash flows. So long as we
reasonably expect that such undiscounted future net cash flows
for each asset will exceed the recorded value of the asset being
evaluated, no impairment is required. However, if plans to sell
or dispose of an asset or group of assets meet a number of
specific criteria, then, under GAAP, such assets should be
considered held for sale or disposition and their recoverability
should be evaluated, based on expected consideration to be
received upon disposition. Sales or dispositions at a particular
time will be affected by, among other things, the existing
industry and general economic circumstances as well as our own
circumstances, including whether or not assets will be sold on
an accelerated or extended timetable. Such circumstances may
cause the expected value in a sale or disposition scenario to
differ materially from the realizable value over the normal
operating life of an asset, which would likely be evaluated on
long-term industry trends.
Income tax provisions in interim periods
In accordance with GAAP, financial statements for interim
periods are to include an income tax provision based on the
effective tax rate expected to be incurred in the current year.
Accordingly, estimates and judgments must be made for each
applicable taxable jurisdiction as to the amount of taxable
income that may be generated, the availability of deductions and
credits expected and the availability of net operating loss
carry-forwards or other tax attributes to offset taxable income.
Making such estimates and judgments is subject to inherent
uncertainties given the difficulty of predicting such factors as
future market conditions, customer requirements, the cost for
key inputs such as energy and primary aluminum, its overall
operating efficiency and many other items.
Predecessor reporting while in reorganization
Consolidated financial statements and information for dates and
periods prior to July 1, 2006 were prepared on a
going concern basis in accordance with
SOP 90-7, and did
not include the impacts of our plan of reorganization including
adjustments relating to recorded asset amounts, the resolution
of liabilities subject to compromise or the cancellation of the
equity interests of our pre-emergence
54
Managements discussion and analysis of financial
condition and results of operations
stockholders. Adjustments related to our plan of reorganization
materially affected our consolidated financial statements
included in this prospectus.
In addition, during the course of the chapter 11 bankruptcy
proceedings, there were material impacts including:
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Additional
pre-filing date claims
were identified through the proof of claim reconciliation
process and arose in connection with our actions in the
chapter 11 bankruptcy proceedings. For example, while we
considered rejection of the Bonneville Power Administration
contract to be in our best long-term interests, the rejection
resulted in an approximate $75.0 million claim by the
Bonneville Power Administration. In the quarter ended
June 30, 2006, an agreement with the Bonneville Power
Administration was approved by the bankruptcy court under which
the claim was settled for a
pre-petition claim of
$6.1 million. |
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The amount of
pre-filing date claims
ultimately allowed by the bankruptcy court related to disputed
claims was materially different from the amount reflected in our
consolidated financial statements. |
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Changes in our business plan
precipitated by the chapter 11 bankruptcy proceedings
resulted in significant charges associated with the disposition
of assets.
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QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
Our operating results are sensitive to changes in the prices of
alumina, primary aluminum and fabricated aluminum products, and
also depend to a significant degree upon the volume and mix of
all products sold. As discussed more fully in Notes 3 and
13 to our consolidated financial statements, we have utilized
hedging transactions to lock in a specified price or range of
prices for certain products which we sell or consume in our
production process and to mitigate our exposure to changes in
foreign currency exchange rates.
Sensitivity
Primary Aluminum
Our share of primary aluminum production from Anglesey is
approximately 150 million pounds annually. Because we
purchase alumina for Anglesey at prices linked to primary
aluminum prices, only a portion of our net revenues associated
with Anglesey are exposed to price risk. We estimate the net
portion of our share of Anglesey production exposed to primary
aluminum price risk to be approximately 100 million pounds
annually (before considering income tax effects).
Our pricing of fabricated aluminum products is generally
intended to lock in a conversion margin (representing the value
added from the fabrication process) and to pass metal price risk
on to our customers. However, in certain instances, we enter
into firm price arrangements. In such instances, we have price
risk on our anticipated primary aluminum purchase for the
customers order. Total fabricated products shipments
during 2003, 2004 and 2005 for which we had price risk were (in
millions of pounds) 97.6, 119.0 and 155.0, respectively,
representing 26%, 26% and 32% of the total pounds of fabricated
products shipped in the applicable year. Total fabricated
products shipments during the nine month periods ended
September 30, 2005 and 2006 for which we had price risk
were (in millions of pounds) 109.6 and 153.0, respectively,
representing 29% and 38% of total fabricated products shipments
in the applicable period.
During the last three years, our net exposure to primary
aluminum price risk at Anglesey substantially offset or roughly
equaled the volume of fabricated products shipments with
underlying primary aluminum price risk. As such, we consider our
access to Anglesey production overall to be a
natural hedge against any fabricated products firm
metal-price risk. However, since the volume of fabricated
products shipped under firm prices may not match up on a
month-to-month basis
with expected
55
Managements discussion and analysis of financial
condition and results of operations
Anglesey-related primary aluminum shipments, we may use
third-party hedging instruments to eliminate any net remaining
primary aluminum price exposure existing at any time.
At September 30, 2006, our fabricated products business
held contracts for the delivery of fabricated aluminum products
that have the effect of creating price risk on anticipated
primary aluminum purchases for the fourth quarter of 2006 and
the period 2007 2010 totaling approximately (in millions
of pounds): 2006: 69, 2007: 116, 2008: 94, and
2009: 71 and 2010: 72.
Foreign currency
From time to time, we enter into forward exchange contracts to
hedge material cash commitments for foreign currencies. After
considering the completed sales of our commodities interests,
our primary foreign exchange exposure is the Anglesey-related
commitment that we fund in Great Britain Pound Sterling. We
estimate that, before consideration of any hedging activities, a
US $0.01 increase (decrease) in the value of the
Great Britain Pound Sterling results in an approximate
$0.5 million (decrease) increase in our annual
pre-tax operating
income.
Energy
We are exposed to energy price risk from fluctuating prices for
natural gas. We estimate that each $1.00 change in natural gas
prices (per thousand cubic feet) impacts our annual
pre-tax operating
results by approximately $4 million.
From time to time, in the ordinary course of business, we enter
into hedging transactions with major suppliers of energy and
energy-related financial investments. As of October 1,
2006, we had fixed price contracts that would cap the average
price we would pay for natural gas so that, when combined with
price limits in the physical gas supply agreement, our exposure
to increases in natural gas prices has been substantially
limited for approximately 76% of the natural gas purchases for
October 2006 through December 2006, approximately 31% of our
natural gas purchases from January 2007 through March 2007 and
approximately 14% of our natural gas purchases from April 2007
through June 2007.
CONTROLS AND PROCEDURES
We maintain disclosure controls and procedures that are designed
to ensure that information required to be disclosed in our
reports under the Securities Exchange Act of 1934, or Exchange
Act, is processed, recorded, summarized and reported within the
time periods specified in the SECs rules and forms and
that such information is accumulated and communicated to
management, including the principal executive officer and
principal financial officer, to allow for timely decisions
regarding required disclosure. In designing and evaluating the
disclosure controls and procedures, management recognizes that
any controls and procedures, no matter how well designed and
operated, can provide only reasonable assurance of achieving the
desired control objectives, and management is required to apply
its judgment in evaluating the cost-benefit relationship of
possible controls and procedures.
Evaluation of disclosure controls and procedures
An evaluation of the effectiveness of the design and operation
of our disclosure controls and procedures was performed as of
December 31, 2005 under the supervision of and with the
participation of our management, including the principal
executive officer and principal financial officer. Based on that
evaluation, our principal executive officer and principal
financial officer concluded that our disclosure controls and
procedures were not effective for the reasons described below.
During the final reporting and closing process relating to our
first quarter of 2005, we evaluated the accounting treatment for
the VEBA payments and concluded that such payments should be
presented
56
Managements discussion and analysis of financial
condition and results of operations
as a period expense. As more fully discussed in Note 16 of
the notes to consolidated financial statements included
elsewhere in this prospectus, during our reporting and closing
process relating to the preparation of our December 31,
2005 financial statements and analyzing the appropriate
post-emergence
accounting treatment for the VEBA payments, we concluded that
the VEBA payments made in 2005 should have been presented as a
reduction of
pre-petition retiree
medical obligations rather than as a period expense. While the
incorrect accounting treatment employed relating to the VEBA
payments did indicate that a deficiency in our internal controls
over financial reporting existed at December 31, 2005, such
deficiency was fully remediated during the final reporting and
closing process in connection with the preparation of our
December 31, 2005 financial statements and, accordingly,
did not exist at the end of subsequent periods.
During the first quarter of 2006 as part of the final reporting
and closing process relating to the preparation of our
December 31, 2005 financial statements, we concluded that
our controls and procedures were not effective as of
December 31, 2005 because a material weakness in internal
control over financial reporting existed relating to our
accounting for derivative financial instruments under Statement
of Financial Accounting Standards No. 133, Accounting
for Derivative Instruments and Hedging Activities
(SFAS No. 133). Specifically, we lacked
sufficient technical expertise as to the application of SFAS
No. 133, and our procedures relating to hedging
transactions were not designed effectively such that each of the
complex documentation requirements for hedge accounting
treatment set forth in SFAS No. 133 were evaluated
appropriately. More specifically, our documentation did not
comply with SFAS No. 133 with respect to our methods
for testing and supporting that changes in the market value of
the hedging transactions would correlate with fluctuations in
the value of the forecasted transaction to which they relate. We
believed that the derivatives we were using would qualify for
the
short-cut
method whereby regular assessments of correlation would not be
required. However, we ultimately concluded that, while the terms
of the derivatives were essentially the same as the forecasted
transaction, they were not identical and, therefore, we should
have done certain mathematical computations to prove the ongoing
correlation of changes in value of the hedge and the forecasted
transaction.
We have concluded that, had we completed our documentation in
strict compliance with SFAS No. 133, the derivative
transactions would have qualified for hedge
(e.g. deferral) treatment. The rules provide that,
once de-designation has
occurred, we can modify our documentation and
re-designate the
derivative transactions as hedges and, if
appropriately documented,
re-qualify the
transactions for prospectively deferring changes in market
fluctuations after such corrections are made.
We are working to modify our documentation and to
re-qualify open and
post-2005 derivative transactions for treatment as hedges.
Specifically, we will, as a part of the
re-designation process,
modify the documentation in respect of all our derivative
transactions to require the long-form method of
testing and supporting correlation. We also intend to have
outside experts review our revised documentation once completed
and to use such experts to perform reviews of documentation in
respect of any new forms of documentation on future transactions
and to do periodic reviews to help reduce the risk that other
instances of
non-compliance with
SFAS No. 133 will occur. However, as
SFAS No. 133 is a complex document and different
interpretations are possible, absolute assurances cannot be
provided that such improved controls will prevent any/all
instances of
non-compliance.
As a result of the material weakness, we restated our financial
statements for the quarters ended March 31, 2005,
June 30, 2005 and September 30, 2005. In light of
these restatements, our management, including our principal
executive officer and principal financial officer, determined
that this deficiency constituted a material weakness in our
internal control over financial reporting at December 31,
2005. Having identified the material weakness prior to the end
of the first quarter of 2006, we changed our accounting for
derivative instruments from hedge treatment to
mark-to-market
treatment in our financial statements for the first quarter of
2006 and subsequent periods in order to
57
Managements discussion and analysis of financial
condition and results of operations
comply with GAAP. While we believe this change in our accounting
for derivative instruments technically resolves the material
weakness from a GAAP perspective, we believe that hedge
accounting is more desirable than mark-to-market accounting
treatment and, accordingly, we will not, from our own
perspective, consider this matter to be fully remediated until
we complete all the steps outlined above and requalify our
derivatives for hedge accounting treatment under GAAP.
Changes in internal controls over financial reporting
We did not have any change in our internal controls over
financial reporting during the third quarter of 2006 that has
materially affected, or is reasonably likely to affect, our
internal controls over financial reporting.
We relocated our corporate headquarters from Houston, Texas to
Foothill Ranch, California. Staff transition occurred starting
in late 2004 and was ongoing primarily during the first half of
2005. A small core group of Houston corporate personnel were
retained throughout 2005 to supplement the Foothill Ranch staff
and handle certain of the remaining chapter 11
bankruptcy-related matters.
As previously announced, in January 2006, our Vice President and
Chief Financial Officer resigned. His decision to resign was
based on a personal relationship with another employee, which we
determined to be inappropriate. The resignation was in no way
related to our internal controls, financial statements,
financial performance or financial condition. We formed the
Office of the CFO and split the CFOs duties
between our Chief Executive Officer and two long-tenured
financial officers, the
VP-Treasurer and
VP-Controller. In
February 2006, a person with a significant corporate accounting
role resigned. This persons duties were split between the
VP-Controller and other
key managers in the corporate accounting group. We also used
certain former personnel to augment the corporate accounting
team. In May 2006, we hired a new CFO, and over recent
months, we have upgraded our corporate accounting and financial
staffs with respect to certain key roles.
The relocation and changes in personnel described above have
made the 2005 year-end
and 2006 accounting and reporting processes more difficult due
to the combined loss of the two individuals and reduced amounts
of institutional knowledge in the new corporate accounting group.
58
Recent reorganization
Between the first quarter of 2002 and the first quarter of 2003,
Kaiser and 25 of our then existing subsidiaries filed voluntary
petitions for relief under chapter 11 of the United States
Bankruptcy Code. While in chapter 11 bankruptcy, we
continued to manage our business in the ordinary course as
debtors-in-possession
subject to the control and administration of the bankruptcy
court.
We and 16 of our subsidiaries filed chapter 11 bankruptcy
in the first quarter of 2002 primarily because of our liquidity
and cash flow problems that arose in late 2001 and early 2002.
We were facing significant near-term debt maturities at a time
of unusually weak aluminum industry business conditions,
depressed aluminum prices and a broad economic slowdown that was
further exacerbated by the events of September 11, 2001. In
addition, we had become increasingly burdened by asbestos
litigation and growing legacy obligations for retiree medical
and pension costs. The confluence of these factors created the
prospect of continuing operating losses and negative cash flows,
resulting in lower credit ratings and an inability to access the
capital markets.
In the first quarter of 2003, nine of our other subsidiaries
filed chapter 11 bankruptcy in order to protect the assets
held by those subsidiaries against possible statutory liens that
might have otherwise arisen and been enforced by the PBGC.
On December 20, 2005, the bankruptcy court entered an order
confirming two separate joint plans of liquidation for four of
our subsidiaries. On December 22, 2005, these plans of
liquidation became effective and all restricted cash and other
assets held on behalf of or by the subsidiaries, consisting
primarily of approximately $686.8 of net cash proceeds from the
sale of interests in and related to certain alumina refineries
in Australia and Jamaica, were transferred to a trustee for
subsequent distribution to holders of claims against the
subsidiaries in accordance with the terms of the plans of
liquidation. In connection with the plans of liquidation, these
four subsidiaries were dissolved and their corporate existence
was terminated.
On February 6, 2006, the bankruptcy court entered an order
confirming a plan of reorganization for us and our other
remaining subsidiaries that had filed chapter 11
bankruptcy. On May 11, 2006, the District Court for the
District of Delaware entered an order affirming the confirmation
order and adopting the bankruptcy courts findings of fact
and conclusions of law regarding confirmation of our plan of
reorganization. On July 6, 2006, our plan of reorganization
became effective and was substantially consummated, whereupon we
emerged from chapter 11 bankruptcy.
Pursuant to our plan of reorganization, on July 6, 2006,
the pre-petition ownership interests in Kaiser were cancelled
without consideration and approximately $4.4 billion of
pre-petition claims against us, including claims in respect of
debt, pension and post-retirement medical obligations and
asbestos and other tort liabilities, were resolved as follows:
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Claims in Respect of Retiree
Medical Obligations.
Pursuant to settlements reached with representatives of hourly
and salaried retirees in early 2004:
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an aggregate of 11,439,900 shares of our common stock were
delivered to the Union VEBA Trust and entities that prior to
July 6, 2006 acquired from the Union VEBA Trust rights to
receive a portion of such shares; and |
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an aggregate of 1,940,100 shares of our common stock were
delivered to the Salaried Retiree VEBA Trust and entities that
prior to July 6, 2006 acquired from the Salaried Retiree
VEBA Trust rights to receive a portion of such shares. |
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Priority Claims and Secured
Claims. All
pre-petition priority claims, pre-petition priority tax claims
and pre-petition secured claims were paid in full in cash.
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Recent reorganization
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Unsecured
Claims. With respect
to pre-petition unsecured claims (other than the personal injury
claims specified below):
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all pre-petition unsecured claims of the PBGC against our
Canadian subsidiaries were satisfied by the delivery of
2,160,000 shares of common stock and $2.5 million in
cash; and |
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all pre-petition general unsecured claims against us, other than
our Canadian subsidiaries, including claims of the PBGC and
holders of our public debt, were satisfied by the issuance of
4,460,000 shares of our common stock to a third-party
disbursing agent, with such shares to be delivered to the
holders of such claims in accordance with the terms of our plan
of reorganization (to the extent that such claims do not
constitute convenience claims that have been or will be
satisfied with cash payments). Of such 4,460,000 shares of
common stock, approximately 250,000 shares were being held
by the third-party disbursing agent as of December 31, 2006
as a reserve pending resolution of disputed claims. To the
extent a holder of a disputed claim is not entitled to shares
reserved in respect of such claim, such shares will be
distributed to holders of allowed claims. |
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Personal Injury
Claims. Certain
trusts, the PI Trusts, were formed to receive distributions from
us, assume responsibility from us for present and future
asbestos personal injury claims, present and future silica
personal injury claims, present and future coal tar pitch
personal injury claims and present but not future noise-induced
hearing personal injury claims, and to make payments in respect
of such personal injury claims. We contributed to the
PI Trusts:
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the rights with respect to proceeds associated with personal
injury-related insurance recoveries reflected on our
consolidated financial statements at June 30, 2006 as a
receivable having a value of $963.3 million; |
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$13.0 million in cash (less approximately $0.3 million
advanced prior to July 6, 2006); |
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the stock of a subsidiary whose primary asset was approximately
145 acres of real estate located in Louisiana and the
rights as lessor under a lease agreement for such real property
that produces modest rental income; and |
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75% of a pre-petition general unsecured claim against one of our
subsidiaries in the amount of $1,106.0 million, entitling
the PI Trusts to a share of the 4,460,000 shares of common
stock distributed to unsecured claimholders. |
The PI Trusts assumed all liability and responsibility for
present and future asbestos personal injury claims, present and
future silica personal injury claims, present and future coal
tar pitch personal injury claims and present but not future
noise-induced hearing personal injury claims. As of July 6,
2006, injunctions were entered prohibiting any person from
pursuing any claims against us or any of our affiliates in
respect of such matters.
In general, the rights afforded under our plan of reorganization
and the treatment of claims under our plan of reorganization are
in complete satisfaction of and discharge all claims arising on
or before July 6, 2006. However, our plan of reorganization
does not limit any rights that the United States of America or
the individual states may have under environmental laws to seek
to enforce equitable remedies against us, though we may raise
any and all available defenses in any action to enforce such
equitable remedies. Further, with regard to certain non-owned
sites specified in the environmental settlement agreement
entered into in connection with our plan of reorganization as to
which we and the United States of America had not reached
settlement by the confirmation date, all our rights and defenses
and those of the United States of America are preserved and not
affected by our plan of reorganization. With respect to sites
owned by us after the confirmation date, specified categories of
claims of the United States of America and the individual states
party to the environmental settlement
60
Recent reorganization
agreement are not discharged, impaired or affected in any way by
our plan of reorganization, and we maintain any and all defenses
to any such claims except for any defense alleging such claims
were discharged under our plan of reorganization.
CORPORATE STRUCTURE
Pursuant to our plan of reorganization, in connection with our
emergence from chapter 11 bankruptcy, we engaged in a
number of transactions in order to simplify our corporate
structure. The following diagram illustrates our corporate
structure as of December 31, 2006:
61
Industry overview
The aluminum fabricated products market is broadly defined as
the markets for flat-rolled, extruded, drawn, forged and cast
aluminum products, which are used in a variety of end-use
applications. We participate in certain portions of the markets
for flat-rolled, extruded/drawn and forged products focusing on
highly engineered products for aerospace and high strength,
general engineering and custom automotive and industrial
applications. The portions of markets in which we participate
accounted for approximately 20% of total North American
shipments of aluminum fabricated products in 2005.
END MARKETS
We have chosen to focus on the manufacture of aluminum
fabricated products primarily for aerospace and high strength,
general engineering and custom automotive and industrial
applications.
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Products sold for aerospace and
high strength applications represented 29% of our 2005
fabricated products shipments. We offer various aluminum
fabricated products to service aerospace and high strength
customers, including heat treat plate and sheet products, as
well as cold finish bars and seamless drawn tubes. Heat treated
products are distinguished from common alloy products by higher
strength, fracture toughness and other desired product
attributes.
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Products sold for general
engineering applications represented 44% of our 2005 fabricated
products shipments. This market consists primarily of
transportation and industrial end customers who purchase a
variety of extruded, drawn and forged fabricated products
through large North American distributors.
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Products sold for custom
automotive and industrial applications represented 27% of 2005
fabricated products shipments. These products include custom
extruded, drawn and forged aluminum products for a variety of
applications. While we are capable of producing forged products
for most end-use applications, we concentrate our efforts on
meeting demand for forged products, other than wheels, in the
automotive industry.
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We have elected not to participate in certain end markets for
fabricated aluminum products, including beverage and food cans,
building and construction materials, and foil used for
packaging, which represented approximately 95% of the North
American flat-rolled products market and approximately 45% of
the North American extrusion market in 2005. We believe our
chosen end markets present better opportunities for sales growth
and premium pricing of differentiated products.
North American Flat-Rolled & Extrusion Market
Size
Kaiser Served & Unserved Segments
Source: 2005 Aluminum Association, Kaiser estimates
62
Industry overview
Aerospace and defense applications
We are a leading supplier of high quality sheet, plate, drawn
tube and bar products to the global aerospace and defense
industry. Our products for these end-use applications are heat
treat plate and sheet, as well as cold finish bar and seamless
drawn tube that are manufactured to demanding specifications.
The aerospace and defense markets consumption of
fabricated aluminum products is driven by overall levels of
industrial production, cyclical airframe build rates and defense
spending, as well as the potential availability of competing
materials such as composites. According to Airline
Monitors July 2006 forecast, the global build rate of
commercial aircraft over 50 seats is expected to rise at a
4.6% compound annual growth rate through 2025. Additionally,
demand growth is expected to increase for thick plate with
growth in monolithic construction of commercial and
other aircraft. In monolithic construction, aluminum plate is
heavily machined to form the desired part from a single piece of
metal (as opposed to creating parts using aluminum sheet,
extrusions or forgings that are affixed to one another using
rivets, bolts or welds). In addition to commercial aviation
demand, military applications for heat treat plate and sheet
include aircraft frames and skins and armor plating to protect
ground vehicles from explosive devices.
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Global Commercial Aircraft Build
> 50 Seats
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U.S. Index of Industrial Production
Seasonally Adjusted |
Source: Airline Monitors July 2006 Forecast
Source: Federal Reserve
General engineering applications
General engineering products consist primarily of standard
catalog items sold to large metal distributors. These products
have a wide range of uses, many of which involve further
fabrication of these products for numerous transportation and
industrial end-use applications where machining of plate, rod
and bar is intensive. Demand growth and cyclicality for general
engineering products tend to mirror broad economic patterns and
industrial activity in North America. Demand is also impacted by
the destocking and restocking of inventory in the full supply
chain.
Custom automotive and industrial applications
We manufacture custom extruded/drawn and forged aluminum
products for many automotive and industrial end uses, including
consumer durables, electrical, machinery and equipment,
automobile, light truck, heavy truck and truck trailer
applications. Examples of the wide variety of custom
63
Industry overview
products that we supply to the automotive industry are extruded
products for anti-lock braking systems, drawn tube for drive
shafts and forgings for suspension control arms and drive train
yokes. For some custom products, we perform limited fabrication,
including sawing and cutting to length. Demand growth and
cyclicality tend to mirror broad economic patterns and
industrial activity in North America, with specific individual
market segments such as automotive, heavy truck and truck
trailer applications tracking their respective build rates.
PRODUCTS AND MANUFACTURING PROCESSES
Flat-Rolled Products
Aluminum rolled products are semi-fabricated plate, sheet and
foil that are further processed into finished goods, including
aluminum cans, automotive body panels, household foil, aircraft
body structures and skins and many other industrial products.
There are two main processes used in the fabrication of
flat-rolled products: (1) a continuous casting process in
which molten aluminum is cast directly into sheets; and
(2) a hot mill process in which heated ingots (large
rectangular slabs of aluminum) are repeatedly squeezed between
large rolls to elongate the ingot to reduce thickness. The
continuous casting process can produce sheet and foil, and the
hot mill process can produce plate, sheet and foil.
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Plate (0.025 inch or
more) Plate is used in heavy duty aerospace, machinery and
transportation applications. Plate applications include
structural sections for rail cars and large ships, structural
components and skins of jumbo jets and spacecraft fuel tanks as
well as armor protection for military vehicles.
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Sheet (0.006 to
0.0249 inch) Sheet is the most widely used form of
aluminum. Sheet applications include packaging (beverage cans
and closures), home appliances and cookware, automobile panels,
aircraft skins and building products such as siding, roofing and
awnings.
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Foil (less than
0.006 inch) Foil is the thinnest of the flat-rolled
aluminum products. Foil applications include flexible packaging,
household foil and fin stock for air conditioning, industrial
and automotive applications.
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We use the hot mill process to produce plate and sheet, but do
not produce foil products. Aluminum rolled products are
manufactured using a variety of alloy mixtures, a range of
tempers (hardness), gauges (thickness) and widths, and
various coatings and finishes. Additional steps can be taken to
achieve desired metallurgical, dimensional and/or performance
properties, including annealing, heat treating, stretching and
leveling.
Extruded and Drawn Products
The extrusion process converts cast billet (a cylindrical log of
aluminum) into semi-finished rods and bars, pipes and tubes, or
profiles for direct end use or further fabrication.
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Rods and Bars Rods and
bars are used in aerospace and general machinery applications.
Examples include rivets, screws, bolts and machinery parts.
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Pipes and Tubes Pipes and
tubes are used in aerospace, automotive, building and
construction and consumer durable applications. Examples include
automotive drive shafts, fluid circulation and control systems
for air conditioning, hydraulics and irrigation, and light poles.
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Profiles (or
shapes) Profiles are used in automotive,
consumer durable and building and construction applications.
Examples include truck trailers, automobile bumpers, heat
distribution systems (heat sinks), doors, windows, commercial
building facades, ladders and scaffolds.
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64
Industry overview
In the extrusion process, the billet is heated to an elevated
temperature to make the metal malleable and then pressed, or
extruded, through a die that gives the material a desired two
dimensional cross section. After the extrusions are straightened
and cut to specified lengths, there can be various processing
and finishing options. Finishing options include polishing,
painting, anodizing and powder coating. Some of our presses can
produce seamless tube, a product with higher structural
integrity than extruded tube with welded seams.
Additionally, extruded tubes and rods can be pulled through a
die, or drawn, to create tubes or rods of more precise
dimensions.
Forged Products
Forging is a manufacturing process in which metal is pressed,
pounded or squeezed under great pressure into high strength
parts known as forgings. Forged parts are heat treated before
final shipment to the customer. The end-use applications are
primarily in transportation, where high
strength-to-weight
ratios in products are valued. We focus our production of forged
products on certain types of automotive applications.
RAW MATERIALS
The rolling ingots used as the starting material for flat-rolled
products and the billets used for extrusions and forgings are
cast from primary aluminum (produced in aluminum smelters),
secondary aluminum (recycled from aluminum scrap such as used
beverage cans and other post-consumer aluminum, as well as
internally generated scrap from internal manufacturing
operations) or a combination thereof. Primary aluminum is
readily available and can generally be purchased at prices set
on the London Metal Exchange plus a premium that varies by
geographic region of delivery, form and alloy. Secondary
aluminum, or scrap, is also readily available and trades at a
discount to primary metal, depending mainly on its alloy and
form.
65
Business
COMPANY OVERVIEW
We are a leading independent fabricated aluminum products
manufacturing company with 2005 net sales of approximately
$1.1 billion. We were founded in 1946 and operate 11
production facilities in the United States and Canada. We
manufacture rolled, extruded, drawn and forged aluminum products
within three product categories consisting of aerospace and high
strength products (which we refer to as Aero/ HS products),
general engineering products and custom automotive and
industrial products.
We produced and shipped approximately 482 million pounds of
fabricated aluminum products in 2005, which comprised 86% of our
total net sales. Of our total fabricated product shipments in
2005, approximately 29% were Aero/ HS products, approximately
44% were general engineering products and the remaining
approximately 27% consisted of custom automotive and industrial
products. Of our total fabricated products net sales in 2005,
approximately 38% were Aero/ HS products, approximately 38% were
general engineering products and the remaining approximately 24%
consisted of custom automotive and industrial products.
In order to capitalize on the significant growth in demand for
high quality heat treat aluminum plate products in the market
for Aero/ HS products, we have begun a major expansion at our
Trentwood facility in Spokane, Washington. We anticipate that
the Trentwood expansion will significantly increase our aluminum
plate production capacity and enable us to produce thicker gauge
aluminum plate. The $105 million expansion will be
completed in phases, with one new heat treat furnace currently
operating at full production, a second such furnace currently
operational and expected to reach full production no later than
early 2007 and a third such furnace becoming operational in
early 2008. A new heavy gauge stretcher, which will enable us to
produce thicker gauge aluminum plate, will also become
operational in early 2008.
We have long-standing relationships with our customers, which
include leading aerospace companies, automotive suppliers and
metal distributors. We strive to tightly integrate the
management of our fabricated products operations across multiple
production facilities, product lines and target markets in order
to maximize the efficiency of product flow to our customers. In
our served markets, we seek to be the supplier of choice by
pursuing
best-in-class
customer satisfaction and offering a product portfolio that is
unmatched in breadth and depth by our competitors.
In addition to our core fabricated products operations, we have
a 49% ownership interest in Anglesey Aluminium Limited, an
aluminum smelter based in Holyhead, Wales. Anglesey has produced
in excess of 140,000 metric tons for each of the last three
fiscal years, of which 49% is available to us. We sell our
portion of Angleseys primary aluminum output to a single
third party at market prices. During 2005, sales of our portion
of Angleseys output represented 14% of our total net
sales. Because we also purchase primary aluminum for our
fabricated products at market prices, Angleseys production
acts as a natural hedge for our fabricated products operations.
Please see Risk factors The expiration of the power
agreement for Anglesey may adversely affect our cash flows and
affect our hedging programs for a discussion regarding the
potential closure of Anglesey, which could occur as soon as 2009.
COMPETITIVE STRENGTHS
We believe that the following competitive strengths will enable
us to enhance our position as one of the leaders in the
fabricated aluminum products industry:
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Leading market positions in
value-added niche markets for fabricated
products. We have
repositioned our business to concentrate on products in which we
believe we have strong
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Business
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production capability, well-developed technical expertise and
high product quality. We believe that we hold a leading market
share position in niche markets that represented approximately
85% of our 2005 net sales from fabricated aluminum
products. Our leading market position extends throughout our
broad product offering, including plate, sheet, seamless
extruded and drawn tube, rod, bar, extrusions and forgings for
use in a variety of value-added aerospace, general engineering
and custom automotive and industrial applications. |
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Well-positioned growth platform. We have substantial
organic growth opportunities in the production of aluminum
plate, extrusions and forgings. We are in the midst of a
$105 million expansion of our Trentwood facility that will
allow us to significantly increase production capacity and
enable us to produce thicker gauge aluminum plate. We also have
the ability to add presses and other manufacturing equipment at
several of our current facilities in order to increase extrusion
and forging capacity. Additionally, we believe our platform and
financial strength provide us with flexibility to create
additional stockholder value through selective acquisitions. |
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Supplier of choice. We pursue
best-in-class
customer satisfaction through the consistent, on-time delivery
of high quality products on short lead times. We offer our
customers a portfolio of both highly engineered and industry
standard products that is unmatched in breadth and depth by most
of our competitors. Our continuous improvement culture is
grounded in our production system, the Kaiser Production System,
which involves an integrated utilization of application and
advanced process engineering and business improvement
methodologies such as lean enterprise, total productive
maintenance and six sigma. We believe that our broad product
portfolio of highly engineered products and the Kaiser
Production System, together with our established record of
product innovation, will allow us to remain the supplier of
choice for our customers and further enhance our competitive
position. |
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Blue-chip customer base and diverse end markets. Our
fabricated products customers include leading aerospace
companies, automotive suppliers and metal distributors, such as
A.M. Castle-Raytheon, Airbus Industrie, Boeing, Bombardier,
Eclipse Aviation, Reliance Steel & Aluminum and
Transtar-Lockheed Martin. We have long-term relationships with
our top customers, many of which we have served for decades. Our
customer base spans a variety of end markets, including
aerospace and defense, automotive, consumer durables, machinery
and equipment, and electrical. |
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Financial strength. We have little debt and significant
liquidity as a result of our recent chapter 11 bankruptcy
reorganization. We also have net operating loss carry-forwards
and other significant tax attributes that may reduce our future
cash payments of U.S. income tax. We previously disclosed
our belief that these tax attributes could together offset in
the range of $555 to $900 million of otherwise taxable
income, and we currently anticipate that, upon completion of our
2006 income tax return analysis, the amount of our tax
attributes as of December 31, 2006 will likely be in the
upper half of that range. |
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Strong and experienced management. The members of our
senior management team have, on average, 20 years of
industry work experience, particularly within the areas of
operations, technology, marketing and finance. Our management
team has repositioned our fabricated products business and led
us through our recent chapter 11 bankruptcy reorganization,
creating a focused business with financial and competitive
strength. |
STRATEGY
Our principal strategies to increase stockholder value are to:
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Pursue organic
growth. We will
continue to utilize our manufacturing platform to increase
growth in areas where we are well-positioned such as aluminum
plate, forgings and extrusions. For
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Business
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instance, we anticipate that the expansion of our Trentwood
facility will enable us to significantly increase our production
capacity and enable us to produce thicker gauge aluminum plate,
allowing us to capitalize on the significant growth in demand
for high quality heat treat aluminum plate products in the
market for Aero/ HS products. Further, our well-equipped
extrusion and forging facilities provide a platform to expand
production as we take advantage of opportunities and our strong
customer relationships in the aerospace and industrial end
markets. |
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Continue to differentiate our products and provide superior
customer support. As part of our ongoing supplier of choice
efforts, we will continue to strive to achieve
best-in-class
customer satisfaction. We will also continue to offer a broad
portfolio of differentiated, superior-quality products with high
engineering content, tailored to the needs of our customers. For
instance, our unique
T-Form®
sheet provides aerospace customers with high formability as well
as requisite strength characteristics, enabling these customers
to substantially lower their production costs. Additionally, we
believe our Kaiser
Select®
Rod established a new industry benchmark for quality and
performance in automatic screw applications. By continually
striving for
best-in-class
customer satisfaction and offering a broad portfolio of
differentiated products, we believe we will be able to maintain
our premium product pricing, increase our sales to current
customers and gain new customers, thereby increasing our market
share. |
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Continue to enhance our operating efficiencies. During
the last five years, we have significantly reduced our costs by
narrowing our product focus, strategically investing in our
production facilities and implementing the Kaiser Production
System. We will continue to implement additional measures to
enhance our operating efficiency and productivity, which we
believe will further decrease our production costs. |
|
|
Maintain financial strength. We intend to employ debt
judiciously in order to remain financially strong throughout the
business cycle and to maintain our flexibility to capitalize on
growth opportunities. |
|
|
Enhance our product portfolio and customer base through
selective acquisitions. We may seek to grow through
acquisitions and strategic partnerships. We will selectively
consider acquisition opportunities that we believe will
complement our product portfolio and add long-term stockholder
value. |
FABRICATED PRODUCTS OPERATIONS
Products
We produced and shipped approximately 482 million pounds of
fabricated aluminum products in 2005, which comprised 86% of our
total net sales. Of our total fabricated product shipments in
2005, approximately 29% were Aero/ HS products, approximately
44% were general engineering products and the remaining
approximately 27% consisted of custom automotive and industrial
products. Of our total fabricated products net sales in 2005,
approximately 38% were Aero/ HS products, approximately 38% were
general engineering products and the remaining approximately 24%
consisted of custom automotive and industrial products.
Aerospace and High Strength Products. Our Aero/ HS
products consist of products that are used in applications that
demand high tensile strength, superior fatigue resistance
properties and exceptional durability even in harsh
environments. For instance, aerospace manufacturers use
high-strength alloys for a variety of structures that must
perform consistently under extreme variations in temperature and
altitude. Our Aero/ HS products are used for a wide variety of
end uses. We make aluminum plate and tube for aerospace
applications, and we manufacture a variety of specialized rod
and bar products that are incorporated in goods as diverse as
baseball bats and racecars.
68
Business
General Engineering Products. Our general engineering
products consist of 6000-series alloy rod, bar, tube, sheet,
plate and standard extrusions. 6000-series alloy is an
extrudable medium-strength alloy that is heat treatable and
extremely versatile. Our general engineering products have a
wide range of uses and applications, many of which involve
further fabrication of these products for numerous
transportation and other industrial end uses. For example, our
products are used in the specialized manufacturing process for
liquid crystal display screens, and we produce aluminum sheet
and plate that are used in the vacuum chambers in which
semiconductors are made. We also produce aluminum plate that is
used to further enhance military vehicle protection. Our rod and
bar products are manufactured into rivets, nails, screws, bolts
and parts of machinery and equipment.
Custom Automotive and Industrial Products. Our custom
products consist of extruded, drawn and forged aluminum products
for applications in many North American automotive and
industrial end uses, including consumer durables, electrical,
machinery and equipment, automobile, light truck, heavy truck
and truck trailer applications. We supply a wide variety of
automotive products, including extruded products for anti-lock
braking systems, drawn tube for drive shafts, and forgings for
suspension control arms and drive train yokes. A significant
portion of our other custom product sales in recent years has
been for water heater anodes, truck trailers and
electrical/electronic heat exchangers.
Fabricated products pricing
The price we pay for primary aluminum, the principal raw
material for our fabricated aluminum products business, consists
of two components: the price quoted for primary aluminum ingot
on the London Metals Exchange, or the LME, and the
Midwest Transaction Premium, a premium to LME reflecting
domestic market dynamics as well as the cost of shipping and
warehousing. Because aluminum prices are volatile, we manage the
risk of fluctuations in the price of primary aluminum through a
combination of pricing policies, internal hedging and financial
derivatives. Our three principal pricing mechanisms are as
follows:
|
|
|
Spot
price. Some of our
customers pay a product price that incorporates the spot price
of primary aluminum in effect at the time of shipment to a
customer. This pricing mechanism typically allows us to pass
commodity price risk to the customer.
|
|
|
Index-based
price. Some of our
customers pay a product price that incorporates an index-based
price for primary aluminum such as Platts Midwest price
for primary aluminum. This pricing mechanism also typically
allows us to pass commodity price risk to the customer.
|
|
|
Fixed
price. Some of our
customers pay a fixed price. During 2003, 2004, 2005 and the
nine months ended September 30, 2006, approximately
97.6 million pounds (or approximately 26%),
119.0 million pounds (or approximately 26%),
155.0 million pounds (or approximately 32%) and
153.0 million pounds (or approximately 38%), respectively,
of our fabricated products were sold at a fixed price. We bear
commodity price risk on fixed-price contracts, which we normally
hedge though a combination of financial derivatives and
production from Anglesey.
|
Sales, marketing and distribution
Sales are made directly to customers by our sales personnel
located in the United States, Canada and Europe, and by
independent sales agents in Asia, Mexico and the Middle East.
Our sales and marketing efforts are focused on the Aero/ HS,
general engineering and custom automotive and industrial product
markets.
Aerospace and High Strength Products. A majority of our
Aero/ HS products are sold to distributors with the remainder
sold directly to customers. Sales are made either under
contracts (with terms spanning from one year to several years)
or on an order-by-order basis. We serve this market with a
69
Business
North American sales force focused on Aero/ HS and general
engineering products and direct sales representatives in Western
Europe. Key competitive dynamics for Aero/ HS products include
the level of commercial aircraft construction spending (which in
turn is often subject to broader economic cycles) and defense
spending.
General Engineering Products. A substantial majority of
our general engineering products are sold to large distributors
in North America, with orders primarily consisting of standard
catalog items shipped with relatively short lead times. We
service this market with a North American sales force focused on
general engineering and Aero/ HS products. Key competitive
dynamics for general engineering products include product price,
product-line breadth, product quality, delivery performance and
customer service.
Custom Automotive and Industrial Products. Our custom
products are sold primarily to first tier automotive suppliers
and industrial end users. Sales contracts are typically medium
to long term in length. Almost all sales of custom products
occur through direct channels using a North American direct
sales force that works closely with our technical sales
organization. Key demand drivers for our automotive products
include the level of North American light vehicle manufacturing
and increased use of aluminum in vehicles in response to
increasingly strict governmental standards for fuel efficiency.
Demand for industrial products is directly linked to the
strength of the U.S. industrial economy.
Kaiser
Selecttm
In 2002, we launched our Kaiser
Selecttm
brand of products to further differentiate the quality of our
general engineering products from those of our competitors. We
are able to produce high-quality Kaiser
Selecttm
products due to our process and application engineering
expertise, research and development resources, equipment design
and the Kaiser Production System, which involves an integrated
utilization of application and advanced process engineering and
business improvement methodologies such as lean enterprise,
total productive maintenance and six sigma. We believe Kaiser
Selecttm
products are the highest quality products in the industry.
Customers
In 2005 and for the nine months ended September 30, 2006,
we had more than 550 and 525 fabricated products customers,
respectively. The largest and top five customers for fabricated
products accounted for approximately 11% and 33%, respectively,
of our net sales in 2005 and 19% and 42%, respectively, of our
net sales for the nine months ended September 30, 2006. The
increase in the percentage of our net sales to our largest
fabricated products is the result of our largest fabricated
products customer, Reliance Steel & Aluminum, acquiring
one of our other top five customers in the second quarter of
2006. Sales to Reliance and the other customer (on a combined
basis) accounted for approximately 19% of our net sales in 2005
and for the nine months ended September 30, 2006. The loss
of Reliance as a customer would have a material adverse effect
on our results of operations and cash flows. However, we believe
our relationship with Reliance is good and the risk of loss of
Reliance as a customer is remote.
Manufacturing processes
We utilize the following manufacturing processes to produce our
fabricated products:
Flat rolling. The traditional manufacturing process for
aluminum flat-rolled products uses ingot, a large rectangular
slab of aluminum, as the starter material. The ingot is
processed through a series of rolling operations, both hot and
cold. Finishing steps may include heat treatment, annealing,
coating, stretching, leveling or slitting to achieve the desired
metallurgical, dimensional and performance characteristics.
Aluminum flat-rolled products are manufactured using a variety
of alloy mixtures, a
70
Business
range of tempers (hardness), gauges (thickness) and widths, and
various coatings and finishes. Flat-rolled aluminum
semi-finished products are generally either sheet (under
0.25 inches in thickness) or plate (up to 15 inches in
thickness). The vast majority of the North American market for
aluminum flat-rolled products uses common alloy
material for construction and other applications and
beverage/food can sheet. However, these are products and markets
in which we have chosen not to participate. Rather, we have
focused our efforts on heat treat products. Heat
treat products are distinguished from common alloy products by
higher strength and other desired product attributes. The
primary end use of heat treat flat-rolled sheet and plate is for
aerospace and general engineering products.
Extrusion. The extrusion process typically starts with a
cast billet, which is an aluminum cylinder of varying length and
diameter. The first step in the process is to heat the billet to
an elevated temperature whereby the metal is malleable. The
billet is put into an extrusion press and pushed, or extruded,
through a die that gives the material the desired
two-dimensional cross section. The material is either quenched
as it leaves the press, or subjected to a post-extrusion heat
treatment cycle, to control the materials physical
properties. The extrusion is then straightened by stretching and
cut to length before being hardened in aging ovens. The largest
end uses of extruded products are in the construction, general
engineering and custom markets. Building and construction
products represents the single largest end-use market for
extrusions by a significant amount. However, we have chosen to
focus our efforts on general engineering and custom products
because we believe we have strong production capability,
well-developed technical expertise and high product quality with
respect to these products.
Drawing. Drawing is a fabrication operation pursuant to
which extruded tubes and rods are pulled through a die, or
drawn. The purpose of drawing is to reduce the diameter and wall
thickness while improving physical properties and dimensions.
Material may go through multiple drawing steps to achieve the
final dimensional specifications. The primary end use of drawn
products is for Aero/ HS products.
Forging. Forging is a manufacturing process in which
metal is pressed, pounded or squeezed under great pressure into
high-strength parts known as forgings. Forged parts are heat
treated before final shipment to the customer. The end-use
applications are primarily in transportation, where high
strength-to-weight
ratios in products are valued. We focus our production on
certain types of automotive applications.
Production facilities
A description of the manufacturing processes utilized and
products made at each of our 11 production facilities is shown
below:
|
|
|
|
|
Location |
|
Manufacturing process |
|
Products |
|
Chandler, Arizona
|
|
Drawing |
|
Aero/HS |
Greenwood, South Carolina
|
|
Forging |
|
Custom |
Jackson, Tennessee
|
|
Extrusion and drawing |
|
Aero/HS and general engineering |
London, Ontario
|
|
Extrusion |
|
Custom |
Los Angeles, California
|
|
Extrusion |
|
General engineering and custom |
Newark, Ohio
|
|
Extrusion and rolling |
|
Aero/HS and general engineering |
Richland, Washington
|
|
Extrusion |
|
Aero/HS and general engineering |
Richmond, Virginia
|
|
Extrusion and drawing |
|
General engineering and custom |
Sherman, Texas
|
|
Extrusion |
|
Custom |
Spokane, Washington
|
|
Rolling |
|
Aero/HS and general engineering |
Tulsa, Oklahoma
|
|
Extrusion |
|
General engineering |
71
Business
Many of our facilities employ the same basic manufacturing
processes and produce the same type of products. Over the past
several years, given the similar economic and other
characteristics at each location, we have made a significant
effort to more tightly integrate the management of our
fabricated products operations across multiple production
facilities, product lines and target markets in order to
maximize the efficiency of product flow to our customers. A
substantial portion of purchasing of primary aluminum for
fabrication is centralized in an effort to maximize price,
payment terms and other benefits. Because many customers
purchase a variety of our products that are produced at
different plants, we have also substantially integrated our
sales force. We believe that integration of our operations
allows us to capture efficiencies while allowing plant personnel
to remain highly focused on particular product lines.
Research and development
We operate three research and development centers. Our Rolling
and Heat Treat Center and our Metallurgical Analysis Center are
both located at our Trentwood facility in Spokane, Washington.
The Rolling and Heat Treat Center has complete hot rolling, cold
rolling and heat treat capabilities to simulate, in small lots,
processing of flat-rolled products for process and product
development on an experimental scale. The Metallurgical Analysis
Center consists of a full metallographic laboratory and a
scanning electron microscope to support research development
programs as well as respond to plant technical service requests.
The third center, our Solidification and Casting Center, is
located in Newark, Ohio and has a short stroke experimental
caster with ingot cast rolling capabilities for the experimental
rolling mill and for extrusion billet used in plant extrusion
trials. Due to our research and development efforts, we have
been able to introduce products such as our unique
T-Form®
sheet which provides aerospace customers with high formability
as well as requisite strength characteristics, enabling these
customers to substantially lower their production costs.
Raw materials
We purchase substantially all of the primary aluminum and
recycled and scrap aluminum used to make our fabricated products
from third-party suppliers. In a majority of the cases, we
purchase primary aluminum ingot and recycled and scrap aluminum
in varying percentages depending on market factors such as price
and availability. Primary aluminum is typically based on the
Average Midwest Transaction Price, or Midwest Price, which has
typically ranged between $0.03 to $0.075 per pound above
the price traded on the LME depending on primary aluminum supply
and demand dynamics in North America. Recycled and scrap
aluminum are typically purchased at a modest discount to ingot
prices but can require additional processing. In addition to
producing fabricated aluminum products for sale to third
parties, certain of our production facilities provide one
another with billet, log or other intermediate materials in lieu
of purchasing such items from third-party suppliers. For
example, a substantial majority of the product from our
Richland, Washington facility is used as base input at our
Chandler, Arizona facility; our Sherman, Texas plant is
currently supplying billet and logs to our Tulsa, Oklahoma
facility; our Richmond, Virginia facility typically receives
some portion of its metal supply from our London, Ontario or
Newark, Ohio facilities, or both; and our Newark, Ohio facility
also supplies billet and log to our Jackson, Tennessee facility
and extruded forge stock to our Greenwood, South Carolina
facility.
PRIMARY ALUMINUM OPERATIONS
We own a 49% interest in Anglesey, which owns an aluminum
smelter at Holyhead, Wales. Rio Tinto Plc owns the remaining 51%
ownership interest in Anglesey and has
day-to-day operating
responsibility for Anglesey, although certain decisions require
the unanimous approval of both shareholders.
72
Business
Anglesey has produced in excess of 140,000 metric tons for each
of the last three fiscal years. We supply 49% of Angleseys
alumina requirements and purchase 49% of Angleseys
aluminum output, in each case based on a market-related pricing
formula. Anglesey produces billet, rolling ingot and sow for the
U.K. and European marketplace. We sell our share of
Angleseys output to a single third party at market prices.
The price received for sales of production from Anglesey
typically approximates the LME price. We also realize a premium
(historically between $0.05 and $0.12 per pound above the
LME price depending on the product) for sales of value-added
products such as billet and rolling ingot.
To meet our obligation to sell alumina to Anglesey in proportion
to our ownership percentage, we purchase alumina under contracts
that extend through 2007 at prices that are tied to market
prices for primary alumina. We will need to secure a new alumina
contract for the period after 2007. We can give no assurance
regarding our ability to secure a source of alumina on
comparable terms. If we are unable to do so, the results of our
primary aluminum operations may be affected.
Anglesey operates under a power agreement that provides
sufficient power to sustain its operations at full capacity
through September 2009. The nuclear facility which supplies
power to Anglesey is scheduled to cease operations shortly
thereafter. Angleseys ability to operate past September
2009 is dependent upon finding adequate power at an acceptable
purchase price. We can give no assurance that Anglesey will be
able to do so. If Anglesey cannot obtain sufficient power,
Angleseys operations will likely be shut down. Given the
potential for future shutdown and related costs, dividends from
Anglesey have been suspended while Anglesey studies future cash
requirements. The shutdown process may involve significant costs
to Anglesey which would decrease or eliminate its ability to pay
future dividends. The process of shutting down operations may
involve transition complications which may prevent Anglesey from
operating at full capacity until the expiration of the power
contract.
COMPETITION
The fabricated aluminum industry is highly competitive. We
concentrate our fabricating operations on selected products for
which we believe we have production capability, technical
expertise, high product quality, and geographic and other
competitive advantages. Competition in the sale of fabricated
aluminum products is driven by quality, availability, price and
service, including delivery performance. Our primary competition
in flat-rolled products is Alcoa, Inc. and Alcan Inc. In the
extrusion market, we compete with many regional participants as
well as larger firms with national reach such as Alcoa, Norsk
Hydro ASA and Indalex. Many of our competitors are substantially
larger, have greater financial resources, and may have other
strategic advantages, including more efficient technologies or
lower raw material and energy costs.
Our fabricated aluminum products facilities are located in North
America. To the extent our competitors have production
facilities located outside North America, they may be able to
produce similar products at a lower cost. We may not be able to
adequately reduce cost to compete with these products. Increased
competition could cause a reduction in our shipment volume and
profitability or increase our expenditures, any one of which
could have a material adverse effect on our results of
operations.
In addition, our fabricated aluminum products compete with
products made from other materials, such as steel and
composites, for various applications, including aircraft
manufacturing. The willingness of customers to accept
substitutions for aluminum and the ability of large customers to
exert leverage in the marketplace to reduce the pricing for
fabricated aluminum products could adversely affect our results
of operations.
For the heat treat plate and sheet products, new competition is
limited by technological expertise that only a few companies
have developed through significant investment in research and
development.
73
Business
Further, use of plate and sheet in safety critical applications
make quality and product consistency critical factors. Suppliers
must pass rigorous qualification process to sell to airframe
manufacturers. Additionally, significant investment in
infrastructure and specialized equipment is required to supply
heat treat plate and sheet.
Barriers to entry are lower for extruded and forged products,
mostly due to the lower required investment in equipment.
However, the products that we produce are somewhat
differentiated from the majority of products sold by
competitors. We maintain a competitive advantage by using
application engineering and advanced process engineering to
distinguish our company and our products. Our metallurgical
expertise and controlled manufacturing processes enable superior
product consistency and are difficult for competitors to offer,
limiting their ability to effectively compete in many of our
product niches.
SEGMENT AND GEOGRAPHICAL AREA FINANCIAL INFORMATION
The information set forth in note 15 to our consolidated
financial statements for the year ended December 31, 2005
regarding our operating segments and our geographical operating
areas is incorporated herein by reference.
EMPLOYEES
At September 30, 2006, we had approximately 2,400
employees, of which approximately 2,360 were employed in the
fabricated products operations and approximately 40 were
employed in our corporate offices in Foothill Ranch, California.
We consider our present relations with our employees to be good.
The table below shows each manufacturing location, the primary
union affiliation, if any, and the expiration date for the
current union contract.
|
|
|
|
|
Location |
|
Union |
|
Contract expiration date |
|
Chandler, Arizona
|
|
Non-union |
|
NA |
Greenwood, South Carolina
|
|
Non-union |
|
NA |
Jackson, Tennessee
|
|
Non-union |
|
NA |
London, Ontario
|
|
USW Canada |
|
February 2009 |
Los Angeles, California
|
|
Teamsters |
|
May 2009 |
Newark, Ohio
|
|
USW |
|
September 2010 |
Richland, Washington
|
|
Non-union |
|
NA |
Richmond, Virginia
|
|
USW/ IAM |
|
November 2010 |
Sherman, Texas
|
|
IAM |
|
December 2007 |
Spokane, Washington
|
|
USW |
|
September 2010 |
Tulsa, Oklahoma
|
|
USW |
|
November 2010 |
As part of our chapter 11 bankruptcy reorganization, we
entered into a settlement with the USW regarding, among other
things, pension and retiree medical obligations. Under the terms
of the settlement, we agreed to adopt a position of neutrality
regarding the unionization of any of our employees.
ENVIRONMENTAL MATTERS
We are subject to numerous environmental laws and regulations
with respect to, among other things: air and water emissions and
discharges; the generation, storage, treatment, transportation
and disposal of solid and hazardous waste; and the release of
hazardous or toxic substances, pollutants and contaminants into
the environment. Compliance with these environmental laws is and
will continue to be costly.
74
Business
Our operations, including our operations conducted prior to our
emergence from chapter 11 bankruptcy, have subjected, and
may in the future subject, us to fines or penalties for alleged
breaches of environmental laws and to obligations to perform
investigations or clean up of the environment. We may also be
subject to claims from governmental authorities or third parties
related to alleged injuries to the environment, human health or
natural resources, including claims with respect to waste
disposal sites, the clean up of sites currently or formerly used
by us or exposure of individuals to hazardous materials. Any
investigation, clean-up or other remediation costs, fines or
penalties, or costs to resolve third-party claims may be costly
and could have a material adverse effect on our financial
position, results of operations and cash flows.
We have accrued, and will accrue, for costs relating to the
above matters that are reasonably expected to be incurred based
on available information. However, it is possible that actual
costs may differ, perhaps significantly, from the amounts
expected or accrued, and such differences could have a material
adverse effect on our financial position, results of operations
and cash flows. In addition, new laws or regulations or changes
to existing laws and regulations may occur, and we cannot assure
you as to the amount that we would have to spend to comply with
such new or amended laws and regulations or the effects that
they would have on our financial position, results of operations
and cash flows.
LEGAL PROCEEDINGS
Between the first quarter of 2002 and the first quarter of 2003,
Kaiser and 25 of our then-existing subsidiaries filed voluntary
petitions for relief under chapter 11 of the United States
Bankruptcy Code. Pursuant to our plan of reorganization, we
emerged from chapter 11 bankruptcy on July 6, 2006.
Notwithstanding the effectiveness of our plan of reorganization,
the bankruptcy court continues to have jurisdiction to, among
other things, resolve disputed pre-petition claims against us,
resolve matters related to the assumption, assumption and
assignment, or rejection of executory contracts pursuant to our
plan of reorganization, and to resolve other matters that may
arise in connection with or related to our plan of
reorganization. Our plan of reorganization resolved all of our
material pre-petition liabilities.
We are working with regulatory authorities and performing
studies and remediation pursuant to several consent orders with
the State of Washington relating to the historical use of oils
containing PCBs at our Trentwood facility in Spokane, Washington
prior to 1978. During April 2004, we were served with a subpoena
for documents and notified by Federal authorities that they are
investigating the alleged non-compliant release of waste water
containing PCBs at our Trentwood facility. This investigation is
ongoing. We believe we are currently in compliance in all
material respects with all applicable environmental laws and
requirements at the Trentwood facility. While we intend to
vigorously defend any claim or charges, if any should result, we
cannot assess what, if any, impact this matter may have on our
financial statements.
Various other lawsuits and claims are pending against us.
Because uncertainties are inherent in the final outcome of such
matters and it is presently impossible to determine the actual
costs that ultimately may be incurred, we do not know whether
that the resolution of such uncertainties and the incurrence of
such costs could have a negative impact on our consolidated
financial position, results of operations or liquidity.
75
Management
EXECUTIVE OFFICERS AND DIRECTORS
The following table sets forth the names and ages of each of the
current executive officers and directors of our company and the
positions they held as of December 31, 2006.
|
|
|
|
|
Name |
|
Age |
|
Position(s) |
|
Jack A. Hockema
|
|
60 |
|
President, Chief Executive Officer and Chairman of the Board;
Director |
Joseph P. Bellino
|
|
56 |
|
Executive Vice President and Chief Financial Officer |
John Barneson
|
|
55 |
|
Senior Vice President and Chief Administrative Officer |
John M. Donnan
|
|
45 |
|
Vice President, Secretary and General Counsel |
Daniel D. Maddox
|
|
46 |
|
Vice President and Controller |
Daniel J. Rinkenberger
|
|
47 |
|
Vice President and Treasurer |
George Becker
|
|
78 |
|
Director |
Carl B. Frankel
|
|
72 |
|
Director |
Teresa A. Hopp
|
|
47 |
|
Director |
William F. Murdy
|
|
64 |
|
Director |
Alfred E. Osborne, Jr., Ph.D.
|
|
62 |
|
Director |
Georganne C. Proctor
|
|
50 |
|
Director |
Jack Quinn
|
|
55 |
|
Director |
Thomas M. Van Leeuwen
|
|
50 |
|
Director |
Brett E. Wilcox
|
|
53 |
|
Director |
Experience of executive officers
Set forth below are brief descriptions of the business
experience of each of our executive officers.
Jack A. Hockema has served as our President and Chief
Executive Officer and a director since October 2001, and as
Chairman of the Board since July 2006. He previously served as
Executive Vice President and President of the Kaiser Fabricated
Products division from January 2000 to October 2001, and
Executive Vice President of Kaiser from May 2000 to October
2001. He served as Vice President of Kaiser from May 1997 to May
2000. Mr. Hockema was President of Kaiser Engineered
Products from March 1997 to January 2000. He served as President
of Kaiser Extruded Products and Engineered Components from
September 1996 to March 1997. Mr. Hockema served as a
consultant to Kaiser and acting President of Kaiser Engineered
Components from September 1995 to September 1996.
Mr. Hockema was an employee of Kaiser from 1977 to 1982,
working at our Trentwood facility, and serving as plant manager
of our former Union City, California can plant and as operations
manager for Kaiser Extruded Products. In 1982, Mr. Hockema
left Kaiser to become Vice President and General Manager of Bohn
Extruded Products, a division of Gulf+Western, and later served
as Group Vice President of American Brass Specialty Products
until June 1992. From June 1992 to September 1996,
Mr. Hockema provided consulting and investment advisory
services to individuals and companies in the metals industry. He
holds a Master of Science degree in Industrial Management and a
Bachelor of Science degree in Civil Engineering, both from
Purdue University.
Joseph P. Bellino has served as our Executive Vice
President and Chief Financial Officer since May 2006. Prior to
joining Kaiser, Mr. Bellino was employed by Steel
Technologies Inc., a flat-rolled steel processor, where he
served as chief financial officer and treasurer for nine years
and was a member of the board of directors from 2002 to 2004.
From 1996 to 1997, Mr. Bellino was president of Beacon
Capital Advisors Company, a consulting firm specializing in
mergers and acquisitions, valuations and executive advisory
services. Prior to 1996, Mr. Bellino held senior executive
positions with a privately
76
Management
held holding company with investments in the manufacturing and
distribution industries for 15 years. Mr. Bellino
holds a Bachelor of Science degree in finance and a Master of
Business Administration degree, both from Ohio State University.
John Barneson has served as our Senior Vice President and
Chief Administrative Officer since August 2001. He previously
served as our Vice President and Chief Administrative Officer
from December 1999 through August 2001. He served as Engineered
Products Vice President of Business Development and Planning
from September 1997 to December 1999. Mr. Barneson served
as Flat-Rolled Products Vice President of Business Development
and Planning from April 1996 to September 1997.
Mr. Barneson has been an employee of Kaiser since September
1975 and has held a number of staff and operation management
positions within the Flat-Rolled and Engineered Products
business units. He holds a Master of Science degree and a
Bachelor of Science degree in Industrial Engineering from Oregon
State University.
John M. Donnan has served as our Vice President,
Secretary and General Counsel since January 2005.
Mr. Donnan joined the legal staff of Kaiser in 1993 and was
named Deputy General Counsel of Kaiser in 2000. Prior to joining
Kaiser, Mr. Donnan was an associate in the Houston, Texas
office of the law firm of Chamberlain, Hrdlicka, White,
Williams & Martin. He holds a Juris Doctorate degree
from the University of Arkansas School of Law and Bachelor of
Business Administration degrees in finance and accounting from
Texas Tech University. He is a member of the Texas and
California bars.
Daniel D. Maddox has served as our Vice President and
Controller since September 1998. He served as our Controller,
Corporate Consolidation and Reporting from October 1997 through
September 1998. Mr. Maddox previously served as our
Assistant Corporate Controller from May 1997 to September 1997.
Mr. Maddox was with Arthur Andersen LLP from 1982 until
joining Kaiser in June 1996. He holds a Bachelor of Business
Administration degree from the University of Texas.
Daniel J. Rinkenberger has served as our Vice President
and Treasurer since January 2005. He previously served as our
Vice President of Economic Analysis and Planning from February
2002 through January 2005. He served as Vice President, Planning
and Business Development of Kaiser Fabricated Products division
from June 2000 through February 2002. Prior to that, he served
as Vice President, Finance and Business Planning of Kaiser
Flat-Rolled Products division from February 1998 to February
2000, and as our Assistant Treasurer from January 1995 through
February 1998. Before joining Kaiser, he held a series of
progressively responsible positions in the Treasury Department
at Pennzoil Corporation. He holds a Master of Business
Administration degree in Finance from the University of Chicago
and a Bachelor of Education degree from Illinois State
University. He is a Chartered Financial Analyst.
Experience of directors
Set forth below are brief descriptions of the business
experience of each of our independent directors.
George Becker has served as a director of Kaiser since
July 2006. Mr. Becker was with the United Steel Workers of
America for more than 40 years until his retirement in
2001, where he served two terms as President, two terms as
International Vice President and two terms as International Vice
President of Administration. Mr. Becker is currently
chairman of the labor advisory committee to the
United States Trade Representative and the Department of
Labor, appointed by President Bill Clinton and reappointed by
President George W. Bush. He is also a member of the
United StatesChina Economic & Security
Review Commission chartered by Congress to study and report on a
wide range of issues. Mr. Becker previously served as an
AFL-CIO vice president, chairing the AFL-CIO Executive
Councils key economic policy committee. During that time
Mr. Becker also served as an executive member of the
International Metalworkers Federation and Chairman of the World
Rubber Council of the International Federation of Chemical,
Energy, Mine and General Workers Unions.
77
Management
Carl B. Frankel has served as a director of Kaiser since
July 2006. Mr. Frankel currently serves as a
union-nominated member of LTV Steel Corporations board of
directors and as a member of the board of directors of Us TOO, a
prostate cancer support and advocacy organization. Previously,
Mr. Frankel was General Counsel to the USW from May 1997
until his retirement in September 2000. Prior to May 1997,
Mr. Frankel served as Assistant General Counsel and
Associate General Counsel of the USW for 29 years. From
1987 through 1999, Mr. Frankel served at the staff level of
the Collective Bargaining Forum, a government sponsored
tripartite committee consisting of government, union and
employer representatives designed to improve labor relations in
the United States. Mr. Frankel is also an elected
fellow of the College of Labor and Employment Lawyers and a
published author of several articles. Mr. Frankel has
earned the Sustained Superior Performance Award from the NLRB,
and the Outstanding Performance Award from the NLRB.
Mr. Frankel earned a Bachelors degree and Juris
Doctorate from the University of Chicago.
Teresa A. Hopp has served as a director of Kaiser since
July 2006. Ms. Hopp currently serves as a board member and
audit committee chair for On Assignment, Inc., a provider of
skilled contract professionals to the life sciences and
healthcare industries, where she is responsible for oversight of
Sarbanes-Oxley compliance. Prior to Ms. Hopps
retirement, she was the Chief Financial Officer for Western
Digital Corporation, a hard disk manufacturer, from January 2000
to October 2001 and its Vice President, Finance from September
1998 to December 1999. Prior to her employment with Western
Digital Corporation, Ms. Hopp was with Ernst &
Young LLP from 1981 where she served as an audit partner for
four years. During her tenure at Ernst & Young LLP, she
managed audit department resource planning and scheduling, and
served as internal education director and information systems
audit and security director. She graduated summa cum laude from
the California State University, Fullerton, with a
Bachelors degree in Business Administration.
William F. Murdy has served as a director of Kaiser since
July 2006. Mr. Murdy has been the Chairman and Chief
Executive Officer of Comfort Systems USA, a commercial heating,
ventilation and air conditioning construction and service
company, since June 2000. Mr. Murdy previously served as
President and Chief Executive Officer of Club Quarters, and
Chairman, President and Chief Executive Officer of Landcare USA,
Inc. Mr. Murdy has also served as President and Chief
Executive Officer of General Investment & Development,
and as President and Managing General Partner with Morgan
Stanley Venture Capital, Inc. He previously served as Senior
Vice President and Chief Operating Officer of Pacific Resources,
Inc. Mr. Murdy currently serves on the board of directors
of Comfort Systems USA and UIL Holdings Corp. He holds a
Bachelor of Science degree in Engineering from the
U.S. Military Academy, West Point, and a Masters
degree in Business Administration from the Harvard Business
School.
Alfred E. Osborne, Jr., Ph.D., has served as a
director of Kaiser since July 2006. Dr. Osborne has been
the Senior Associate Dean at the UCLA Anderson School of
Management since July 2003 and an Associate Professor of Global
Economics and Management since July 1978. From July 1987 to June
2003, Dr. Osborne served as the Director of the Harold and
Pauline Price Center for Entrepreneurial Studies at the UCLA
Anderson School of Management. He also served as Faculty
Director of The Head Start Johnson & Johnson Management
Fellows Program. Previously, he held various administrative
posts at UCLA, including terms as chairman of the Business
Economics faculty and Director of the MBA program.
Dr. Osborne currently serves on the board of directors of
K2, Inc., EMAK Worldwide, Inc., FPA New Income Fund Inc.,
FPA Capital Fund Inc. and FPA Crescent Fund, Inc. and
serves as a trustee of the WM Group of Funds. He holds a
Doctorate degree in Business Economics, a Masters degree
in Business Administration, a Master of Arts degree in Economics
and a Bachelors degree in Electrical Engineering from
Stanford University.
Georganne C. Proctor has served as a director of Kaiser
since July 2006. Ms. Proctor is currently the Executive
Vice President and Chief Financial Officer of TIAA-CREF, a
financial services company.
78
Management
Previously, Ms. Proctor was the Executive Vice
PresidentFinance for Golden West Financial Corp., the
second largest financial thrift in the United States and holding
company of World Savings Bank, from February 2003 to April 2005.
From July 1997 through September 2002, Ms. Proctor was
Senior Vice President and Chief Financial Officer of Bechtel
Corporation and served as the Vice President and Chief Financial
Officer of Bechtel Enterprises, one of its subsidiaries, from
June 1994 through June 1997. Ms. Proctor was a member of
the board of directors of Bechtel Corporation from April 1999 to
December 2002. She also served in several other financial
positions with the Bechtel Group from
1982-1991. From 1991
through 1994, Ms. Proctor was Director of Project and
Division Finance of Walt Disney Imagineering and Director of
Finance & Accounting for Buena Vista Home Video
International. Ms. Proctor currently serves on the board of
directors of Redwood Trust, Inc. She holds a Masters
degree in Business Administration from California State
University, Hayward, and a Bachelors degree in Business
Administration from the University of South Dakota.
Jack Quinn has served as a director of Kaiser since July
2006. Mr. Quinn has been the President of
Cassidy & Associates, a government relations firm,
since January 2005. Mr. Quinn assists clients to promote
policy and appropriations objectives in Washington, D.C.
with a focus on transportation, aviation, railroad, highway,
infrastructure, corporate and industry clients. From January
1993 to January 2005, Mr. Quinn served as a
United States Congressman for the state of New York.
While in Congress Mr. Quinn was Chairman of the
Transportation and Infrastructure Subcommittee on Railroads. He
was also a senior member of the Transportation Subcommittees on
Aviation, Highways and Mass Transit. In addition, Mr. Quinn
was Chairman of the Executive Committee in the Congressional
Steel Caucus. Prior to his election to Congress, Congressman
Quinn served as supervisor of the town of Hamburg, New York.
Mr. Quinn currently serves as a trustee of the AFL-CIO
Housing Investment Trust. Mr. Quinn received a
Bachelors degree from Siena College in Loudonville,
New York, and a Masters degree from the State
University of New York, Buffalo. Mr. Quinn received
honorary Doctorate of Law degrees from Medaille College and
Siena College. Mr. Quinn is also a certified school
district superintendent through the New York State
Education Department.
Thomas M. Van Leeuwen has served as a director of Kaiser
since July 2006. Mr. Van Leeuwen served as a
DirectorSenior Equity Research Analyst for Deutsche Bank
Securities Inc. from March 2001 until his retirement in May
2002. Prior to that, Mr. Van Leeuwen served as a
DirectorSenior Equity Research Analyst for Credit Suisse
First Boston from May 1993 to November 2000. Prior to that time,
Mr. Van Leeuwen was First Vice President of Equity Research
with Lehman Brothers. Mr. Van Leeuwen held the position of
research analyst with Sanford C. Bernstein & Co., Inc.,
and systems analyst with The Procter & Gamble Company.
Mr. Van Leeuwen holds a Masters degree in Business
Administration from the Harvard Business School and a Bachelor
of Science degree in Operations Research and Industrial
Engineering from Cornell University.
Brett E. Wilcox has served as a director of Kaiser since
July 2006. Mr. Wilcox has been an executive consultant for
a number of metals and energy companies since 2005. From 1986 to
2005, Mr. Wilcox served as Chief Executive Officer of
Golden Northwest Aluminum Company and its predecessors. Golden
Northwest Aluminum Company, together with its subsidiaries,
filed a petition for reorganization under the United States
Bankruptcy Code on December 22, 2003. Mr. Wilcox has
also served as Executive Director of Direct Services Industries,
Inc., a trade association of large aluminum and other
energy-intensive companies; an attorney with Preston,
Ellis & Gates in Seattle, Washington; Vice Chairman of
the Oregon Progress Board; a member of the Oregon
Governors Comprehensive Review of the Northwest Regional
Power System; a member of the Oregon Governors Task Forces
on structure and efficiency of state government, employee
benefits and compensation, and government performance and
accountability. Mr. Wilcox serves as a director of Oregon
Steel Mills, Inc. Mr. Wilcox received a Bachelors
degree from the Woodrow Wilson School of Public and
International Affairs at Princeton University and a Juris
Doctorate from Stanford Law School.
79
Management
BOARD OF DIRECTORS
Our board of directors currently has ten members, consisting of
Mr. Hockema, our President and Chief Executive Officer, and
nine independent directors, Messrs. Becker, Frankel, Murdy,
Osborne, Quinn, Van Leeuwen and Wilcox and Mmes. Hopp and
Proctor. Mr. Hockema serves as the Chairman of the Board,
and Dr. Osborne serves as the lead independent director.
Our certificate of incorporation and bylaws provide for a
classified board of directors consisting of three classes. The
term of the initial Class I directors will expire at the
2007 annual meeting of the stockholders; the term of the initial
Class II directors will expire at the 2008 annual meeting
of the stockholders; and the term of the Class III
directors will expire at the 2009 annual meeting of the
stockholders. Beginning in 2007, at each annual meeting of
stockholders, successors to the class of directors whose terms
expire in that year will be elected to three-year terms and
until their respective successors are elected and qualified. The
following table sets forth the class of each director.
|
|
|
|
|
Name |
|
|
|
|
Class | |
| |
Alfred E. Osborne, Jr., Ph.D.
|
|
|
Class I |
|
Jack Quinn
|
|
|
Class I |
|
Thomas M. Van Leeuwen
|
|
|
Class I |
|
George Becker
|
|
|
Class II |
|
Jack A. Hockema
|
|
|
Class II |
|
Georganne C. Proctor
|
|
|
Class II |
|
Brett E. Wilcox
|
|
|
Class II |
|
Carl B. Frankel
|
|
|
Class III |
|
Teresa A. Hopp
|
|
|
Class III |
|
William F. Murdy
|
|
|
Class III |
|
DIRECTOR INDEPENDENCE
Our board of directors was reconstituted upon our emergence from
chapter 11 bankruptcy. Our corporate governance guidelines,
adopted upon our emergence from chapter 11 bankruptcy,
require that a majority of the members of our board of directors
satisfy the independence requirements set forth in the Nasdaq
Marketplace Rules and other applicable criteria of the National
Association of Securities Dealers, or NASD. We refer to these
requirements as the general independence criteria. Additionally,
our audit committee charter, compensation committee charter and
nominating and corporate governance committee charter, each
adopted upon our emergence from chapter 11 bankruptcy,
require that all respective committee members satisfy the
general independence criteria.
Based upon information requested from and provided by each
director concerning their background, employment and
affiliations, including family relationships, our board of
directors has determined that each of Messrs. Becker, Frankel,
Murdy, Osborne, Quinn, Van Leeuwen and Wilcox and Mmes. Hopp and
Proctor, representing nine of our ten directors, satisfy the
general independence criteria and are independent within the
meaning of such term under our corporate governance guidelines.
In making such determination, the board of directors considered
the relationships that each of the directors had with our
company and all other facts and circumstances the board of
directors deemed relevant in determining the independence of
each of the directors in accordance with the general
independence criteria, including the fees paid to such
individuals for attending meetings prior to our emergence from
chapter 11 bankruptcy and their formal appointment as
directors.
Prior to our emergence from chapter 11 bankruptcy, we were
not listed on a national securities exchange and, consequently,
the members of our board of directors as constituted prior to
our emergence from chapter 11 bankruptcy were not subject
to independence requirements. However, our board of directors as
constituted prior to emergence determined that, of its six
members,
80
Management
Robert J. Cruikshank, Ezra G. Levin and
John D. Roach satisfied the independence requirements
standards set forth in both the Nasdaq Marketplace Rules and the
New York Stock Exchange Listed Company Manual and that
George T. Haymaker, Jr.,
Jack A. Hockema and Charles E. Hurwitz did
not meet such independence standards. Prior to our emergence,
Messrs. Cruikshank and Roach were members of our audit
committee, Messrs. Cruikshank, Roach and Levin were members of
our compensation policy committee and Mr. Cruikshank was
the sole member of our Section 162(m) compensation
committee. We did not have a nominating and corporate governance
committee prior to our emergence from chapter 11 bankruptcy.
DIRECTOR DESIGNATION AGREEMENT WITH THE USW
On July 6, 2006, we entered into a Director Designation
Agreement with the USW under which the USW has certain rights to
nominate individuals to serve on our board of directors and
committees until December 31, 2012. The USW has the right
to nominate, for submission to our stockholders for election at
each annual meeting, the minimum number of candidates necessary
to ensure that, assuming such candidates are included in the
slate of director candidates recommended by our board of
directors in our proxy statement relating to the annual meeting
and our stockholders elect each candidate so included, at least
40% of the members of our board of directors immediately
following such election are directors who were either designated
by the USW pursuant to our plan of reorganization or have been
nominated by the USW in accordance with the Director Designation
Agreement. The Director Designation Agreement contains
requirements as to the timeliness, form and substance of the
notice the USW must give to our nominating and corporate
governance committee in order to nominate such candidates. The
nominating and corporate governance committee will determine in
good faith whether each candidate properly submitted by the USW
satisfies the qualifications set forth in the Director
Designation Agreement. If our nominating and corporate
governance committee determines that such candidate satisfies
the qualifications, the committee will, unless otherwise
required by its fiduciary duties, recommend such candidate to
our board of directors for inclusion in the slate of directors
to be recommended by the board of directors in our proxy
statement. The board of directors will, unless otherwise
required by its fiduciary duties, accept the recommendation and
include the director candidate in the slate of directors the
board of directors recommends.
The Director Designation Agreement also provides that the USW
will have the right to nominate an individual to fill a vacancy
on the board of directors resulting from the death, resignation,
disqualification or removal of a director who was either
designated by the USW to serve on the board of directors
pursuant to our plan of reorganization or has been nominated by
the USW in accordance with the Director Designation Agreement.
The Director Designation Agreement further provides that, in the
event of newly created directorships resulting from an increase
in the number of our directors, the USW will have the right to
nominate the minimum number of individuals to fill such newly
created directorships necessary to ensure that at least 40% of
the members of the board of directors immediately following the
filling of the newly created directorships are directors who
were either designated by the USW pursuant to our plan of
reorganization or have been nominated by the USW in accordance
with the Director Designation Agreement. In each such case, the
USW, our nominating and corporate governance committee and the
board of directors will be required to follow the nomination and
approval procedures described above.
81
Management
A candidate nominated by the USW may not be an officer,
employee, director or member of the USW or any of its local or
affiliated organizations as of the date of his or her
designation as a candidate or election as a director. Each
candidate nominated by the USW must satisfy:
|
|
|
the general independence
criteria;
|
|
|
the qualifications to serve as a
director as set forth in any applicable corporate governance
guidelines adopted by the board of directors and policies
adopted by our nominating and corporate governance committee
establishing criteria to be utilized by it in assessing whether
a director candidate has appropriate skills and experience; and
|
|
|
any other qualifications to
serve as director imposed by applicable law.
|
Finally, the Director Designation Agreement provides that, so
long as our the board of directors maintains an audit committee,
executive committee or nominating and corporate governance
committee, each such committee will, unless otherwise required
by the fiduciary duties of the board of directors, include at
least one director who was either designated by the USW to serve
on the board of directors pursuant to our plan of reorganization
or has been nominated by the USW in accordance with the Director
Designation Agreement (provided at least one such director is
qualified to serve on such committee as determined in good faith
by the board of directors).
Current members of our board of directors that were designated
by the USW pursuant to our plan of reorganization are
Messrs. Becker, Frankel, Quinn and Wilcox.
COMMITTEES OF THE BOARD OF DIRECTORS
Currently, we have four standing committees of the board of
directors: an executive committee; an audit committee; a
compensation committee; and a nominating and corporate
governance committee.
Executive committee
The executive committee of the board of directors manages our
business and affairs that require attention prior to the next
regular meeting of our board of directors. However, the
executive committee does not have the power to (1) approve
or adopt, or recommend to our stockholders, any action or matter
expressly required by law to be submitted to our stockholders
for approval, (2) adopt, amend or repeal any bylaw of our
company, or (3) take any other action reserved for action
by the board of directors pursuant to a resolution of the board
of directors or otherwise prohibited to be taken by the
executive committee by law or pursuant to our certificate of
incorporation or bylaws. The members of the executive committee
must include the Chairman of the Board and at least one of the
directors either designated by the USW pursuant to our plan of
reorganization or nominated by the USW in accordance with the
Director Designation Agreement (so long as at least one such
director is qualified to serve thereon). A majority of the
members of the executive committee must satisfy the general
independence criteria as determined by the board of directors
reasonably and in good faith. Our executive committee consists
of Messrs. Hockema, Becker and Wilcox and Ms. Hopp.
Mr. Hockema currently serves as the chair of the executive
committee.
Audit committee
The audit committee oversees our accounting and financial
reporting practices and processes and the audits of our
financial statements on behalf of the board of directors. The
audit committee is
82
Management
responsible for appointing, compensating, retaining and
overseeing the work of our independent auditors. Other duties
and responsibilities of the audit committee include:
|
|
|
establishing hiring policies for
employees or former employees of the independent auditors;
|
|
|
reviewing our systems of
internal accounting controls;
|
|
|
discussing risk management
policies;
|
|
|
approving related-party
transactions;
|
|
|
establishing procedures for
complaints regarding financial statements or accounting
policies; and
|
|
|
performing other duties
delegated to the audit committee by the board of directors from
time to time.
|
The members of the audit committee must include at least one of
the directors either designated by the USW pursuant to our plan
of reorganization or nominated by the USW in accordance with the
Director Designation Agreement (so long as at least one such
director is appropriately qualified). Each member of the audit
committee:
|
|
|
must satisfy the general
independence criteria;
|
|
|
may not, other than as a member
of the board of directors or a committee thereof, accept any
consulting, advisory or other compensatory fee from us or our
subsidiaries (other than fixed amounts of compensation under a
retirement plan for prior service, provided such compensation is
not contingent on continued service);
|
|
|
may not be our affiliate;
|
|
|
must not have participated in
the preparation of our financial statements at any time during
the three years prior to July 6, 2006; and
|
|
|
must be able to read and
understand fundamental financial statements.
|
At least one member of the audit committee must have past
employment experience in finance or accounting, the requisite
professional certification in accounting or comparable
experience or background that results in financial
sophistication. Our audit committee consists of Mmes. Hopp and
Proctor and Messrs. Osborne, Van Leeuwen and Wilcox.
Ms. Hopp currently serves as the chair of the audit
committee.
Compensation committee
The compensation committee of the board of directors establishes
and administers our policies, programs and procedures for
compensating our senior management, including determining and
approving the compensation of our executive officers. Other
duties and responsibilities of the compensation committee
include:
|
|
|
administering plans adopted by
the board of directors that contemplate administration by the
compensation committee, including our 2006 Equity and
Performance Incentive Plan;
|
|
|
overseeing regulatory compliance
with respect to compensation matters;
|
|
|
reviewing director compensation;
and
|
|
|
performing other duties
delegated to the compensation committee by the board of
directors from time to time.
|
83
Management
Each member of the compensation committee must satisfy the
general independence criteria, as well as qualify as a
non-employee
director within the meaning of
Rule 16b-3 of the
Exchange Act. Our compensation committee is composed of
Messrs. Murdy and Quinn and Ms. Proctor.
Mr. Murdy currently serves as the chair of the compensation
committee.
Nominating and corporate governance committee
The nominating and corporate governance committee of the board
of directors identifies individuals qualified to become members
of our board of directors, recommends candidates to fill
vacancies and newly-created positions on our board of directors,
recommends director nominees for the election by stockholders at
the annual meetings of stockholders and develops and recommends
to the board of directors our corporate governance principles.
Other duties and responsibilities of the nominating and
corporate governance committee include:
|
|
|
evaluating stockholder
recommendations for director nominations;
|
|
|
assisting in succession planning;
|
|
|
considering possible conflicts
of interest of members of the board of directors and management
and making recommendations to prevent, minimize or eliminate
such conflicts of interests;
|
|
|
making recommendations to the
board of directors regarding the appropriate size of the board
of directors; and
|
|
|
performing other duties
delegated to the nominating and corporate governance committee
by the board of directors from time to time.
|
The members of the nominating and corporate governance committee
must include at least one of the directors either designated by
the USW pursuant to our plan of reorganization or nominated by
the USW in accordance with the Director Designation Agreement
(so long as at least one such director is appropriately
qualified). Each member of the nominating and governance
committee must satisfy the general independence criteria. Our
nominating and corporate governance committee consists of
Messrs. Osborne, Frankel, Murdy, Quinn and Van Leeuwen.
Dr. Osborne currently serves as the chair of the nominating
and corporate governance committee.
84
Management
EXECUTIVE COMPENSATION
The following discussion of executive compensation contains
descriptions of various employee benefit plans and
employment-related agreements. These descriptions are qualified
in their entirety by reference to the full text or detailed
descriptions of the plans and agreements which are filed as
exhibits to our registration statement of which this prospectus
forms a part.
Compensation discussion and analysis
Introduction
This section provides (1) an overview of the compensation
committee of the board of directors, (2) a discussion of
the background and objectives of our compensation programs for
senior management, and (3) a discussion of all material
elements of the compensation of each of the executive officers
identified in the following table, whom we refer to as our named
executive officers:
|
|
|
Name |
|
Title |
|
Jack A. Hockema
|
|
President and Chief Executive Officer (our principal executive
officer) |
Joseph P. Bellino
|
|
Executive Vice President and Chief Financial Officer (our
principal financial officer) |
John Barneson
|
|
Senior Vice President and Chief Administrative Officer |
John M. Donnan
|
|
Vice President, Secretary and General Counsel |
Daniel D. Maddox
|
|
Vice President and Controller (our principal accounting officer) |
Kerry A. Shiba
|
|
Former Vice President and Chief Financial Officer (our former
principal financial officer) |
The year ended December 31, 2006 was a transition year for
us. It was also a transition year for the board of directors and
our compensation programs. On July 6, 2006, we emerged from
chapter 11 bankruptcy, and a new board of directors
selected by our pre-emergence creditors was installed at that
time.
In contemplation of our emergence from chapter 11
bankruptcy, the individuals expected to serve on the
compensation committee at emergence began an extensive review of
all aspects of our executive compensation programs in early
2006. Based on their review and discussions with the other
individuals expected to serve on the board of directors at
emergence, a comprehensive compensation structure was approved
for implementation upon our emergence.
Overview of the compensation committee
As indicated above, the compensation committee of the board of
directors is comprised entirely of independent directors. The
compensation committees primary duties and
responsibilities are to establish and implement our compensation
policies and programs for senior management. The compensation
committee has the authority under its charter to engage the
services of outside advisors, experts and others to assist it
and has engaged an outside compensation consultant to advise it
on all matters related to compensation of our chief executive
officer and other members of senior management. We refer to the
outside compensation consultant engaged by the compensation
committee as our outside compensation consultant.
Our chief executive officer, other members of our management and
outside advisors may be invited to attend all or a portion of a
compensation committee meeting depending on the nature of the
agenda items. Neither our chief executive officer nor any other
member of management votes on items before the compensation
committee; however, the compensation committee and board of
directors solicit the views of the chief executive officer on
compensation matters, including as they relate to the
compensation of the other named executive officers and members
of senior management reporting to
85
Management
the chief executive officer, including the other named executive
officers. The compensation committee also works with our senior
management to determine the agenda for each meeting, and our
human resources department, with the assistance of our outside
advisors, prepares the meeting materials.
Objectives of our compensation program
The comprehensive compensation structure implemented upon our
emergence from chapter 11 bankruptcy was developed based on
the following objectives:
|
|
|
Create alignment between senior
management and stockholders by rewarding senior management for
the achievement of strategic goals that successfully drive our
operations and enhance stockholder value;
|
|
|
Attract, motivate and retain
highly experienced executives vital to our short-term and
long-term success, profitability and growth;
|
|
|
Differentiate senior management
rewards based on actual performance; and
|
|
|
Provide targeted compensation
levels consistent with the 50th percentile of our
compensation peer group, which is discussed below, for base
salary, the 50th percentile for annual monetary incentives
at target-level performance and between the 50th and the
65th percentile for annualized economic equity grant value
of long-term incentives.
|
Design of our compensation program
The compensation program for senior management, including the
named executive officers, is intended to reinforce the
importance of performance and accountability at both the
individual and corporate levels. In addition to focusing on
pay for performance, our compensation program is
designed to:
|
|
|
Balance short-term and long-term
goals (approximately 50% of the chief executive officers
target total compensation is delivered through long-term
incentives, while approximately 40% of the target total
compensation for the other named executive officers is delivered
through long-term incentives);
|
|
|
Deliver a mix of fixed and
at-risk compensation (by design, approximately 70% of the chief
executive officers target total compensation and
approximately 60% of the target total compensation for the other
named executive officers is variable, i.e., at-risk,
annual and long-term incentive compensation) that is directly
related to stockholder value and our overall performance;
|
|
|
Provide guidelines for a
compensation program that is competitive with our compensation
peer group; and
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|
Use equity-based awards, stock
ownership guidelines and annual incentives that are linked to
stockholder value and achievement of individual, business unit
and corporate performance.
|
Each element of compensation is reviewed individually and
considered collectively with the other elements of our
compensation program to ensure that it is consistent with the
goals and objectives of both that particular element of
compensation and our overall compensation program.
In designing the compensation program and in determining senior
management compensation, including the compensation of the named
executive officers, we also considered the following factors:
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The external challenges to our
ability to attract and retain strong senior management;
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Each individuals
contributions to our overall results;
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Our operating and financial
performance compared with the targeted goals; and
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|
Our size and complexity compared
with companies in our compensation peer group.
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86
Management
We also use tally sheets that provide a summary of
the compensation history of our chief executive officer and
those members of senior management reporting to the chief
executive officer. These tally sheets include a historical
summary of base salary, annual bonus and long-term equity
awards. They also provide a review of wealth and retirement
accumulation as a result of employment with our company.
In developing the compensation structure that was effective upon
our emergence from chapter 11 bankruptcy, we reviewed the
compensation and benefit practices, as well as levels of pay, of
a compensation peer group of companies. The selection of an
appropriate peer group was an important part of the work
performed by the individuals expected to serve on the
compensation committee at emergence. Working closely with our
outside compensation consultant, the companies selected were
determined to: (1) be of a similar size; (2) have
positions of similar complexity and scope of responsibility; and
(3) compete with us for talent. The selected companies
include companies in similar industries, as well as companies in
different industries. While we will continue to review, evaluate
and update the compensation peer group, for the compensation
structure developed in 2006 in anticipation of our emergence
from chapter 11 bankruptcy the compensation peer group
consisted of 41 companies. As we developed the peer group, we
also determined that it was appropriate to design programs that
deliver total compensation between the 50th and 65th percentiles
of the compensation peer group. However, we also recognize that
we compete with much larger companies that aggressively recruit
for the best qualified talent in particularly critical functions
and that to attract and retain that talent, we may determine
that it is in the best interests of our company and stockholders
to provide packages that deviate from the targeted pay
objectives.
Background of our compensation programs
This section will focus on 2006 compensation and our
post-emergence compensation programs. It also addresses certain
aspects of our key employee retention program, which was
implemented in 2002 during our chapter 11 bankruptcy with
the support of our creditors and approval of the bankruptcy
court in order to meet the dual goals of (1) providing the
retention incentives necessary to retain certain key employees
who were expected to remain with us through our emergence from
chapter 11 bankruptcy, assume the additional administrative
and operational burdens imposed on us during chapter 11
bankruptcy and take the actions necessary to improve our
operating performance and strategic positioning during the
chapter 11 bankruptcy and (2) addressing the financial
constraints and obligations to creditors faced by companies in
chapter 11 bankruptcy. We refer to the key employee
retention program as the Chapter 11 KERP. Among other
elements, the Chapter 11 KERP included:
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|
|
a two-year retention plan (which
we refer to as our Chapter 11 Retention Plan) that provided
semi-annual retention payments to key employees through
March 31, 2004, with a significant portion of those
payments to certain senior employees, including
Messrs. Hockema and Barneson, being withheld and paid,
subject to certain conditions relating to continued employment,
in two installments the first on the date of
emergence and the second one year later, all as more fully
described below (see Chapter 11 Retention
Plan and footnote 8 under Summary
compensation table for 2006);
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|
a long-term incentive plan
(which we refer to as our Chapter 11 Long-Term Incentive
Plan) designed to provide incentives for key employees to
achieve cost reductions in excess of $80 million annually,
with all awards earned being withheld and paid, subject to
certain conditions relating to continued employment, in two
installments the first on the date of emergence and
the second one year later, all as more fully described below
(see Long-term incentives and footnote 2
under Summary compensation table for 2006);
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|
a severance plan (which we refer
to as our Severance Plan) and related agreements designed to
provide key employees with job security in an uncertain
environment, as more fully described below
|
87
Management
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|
(see Employment contracts, termination of
employment arrangements and change in control agreements
and Employment-related agreements and certain
employee benefit plans Severance Plan); |
|
|
change-in-control severance agreements (which we refer to as
Change in Control Agreements) intended to retain key employees
through any potential merger or acquisition transaction, as more
fully described below (see Employment contracts,
termination of employment arrangements and change in control
agreements and Employment-related agreements
and certain employee benefit plans Change in control
severance agreements); and |
|
|
the continuance for key employees of our then-existing
nonqualified, unfunded supplemental executive retirement plan
(which we refer to as our Old Restoration Plan) intended to
restore benefits that would be payable to participants in the
Kaiser Aluminum Salaried Employees Retirement Plan, a defined
benefit pension plan previously maintained by us for our
salaried employees (which we refer to as our Old Pension Plan),
but for legal limitations on benefit accruals and payments
thereunder, as more fully described below (see
Retirement benefits and Nonqualified deferred
compensation for 2006). |
Retention of our senior management was determined to be
important to our successful emergence from chapter 11
bankruptcy. Implemented in 2002 with the support of creditors
and approval of the bankruptcy court, a discussion of certain
elements of the Chapter 11 KERP is relevant to any
discussion of (1) compensation received by our named
executive officers in 2006, (2) compensation accrued to our
named executive officers during our chapter 11 bankruptcy,
but payable in 2007, (3) the rights of our named executive
officers upon termination of employment, and (4) the
comprehensive compensation structure implemented upon our
emergence from chapter 11 bankruptcy. This is particularly
true because, as indicated above, several elements of the
Chapter 11 KERP were designed to enhance retention of
key employees by conditioning payments on continued employment
and withholding payments until at and after our emergence.
Elements of compensation
Our compensation program currently consists of base salary,
annual cash incentives, long-term incentives, retirement
benefits and certain perquisites. In addition, we impose stock
ownership requirements on senior management and provide for
general severance and change-in-control protections for certain
members of senior management, including each of the named
executive officers. We have also entered into employment
agreements with Messrs. Hockema, Bellino and Maddox.
Base salary
We review base salaries for our chief executive officer and
those members of senior management reporting to the chief
executive officer and determine if a change is appropriate. In
reviewing base salaries, we consider several factors, including
level of responsibility, prior experience, a comparison to base
salaries paid for comparable positions in our compensation peer
group and the relationship among base salaries paid within our
company. Our intent is to fix base salaries at levels that we
believe are consistent with our program design objectives,
including the ability to attract, motivate and retain
individuals in a competitive environment.
During 2006, we did not increase the base salary of
Mr. Hockema or Mr. Donnan. Mr. Hockemas
base salary remained at the same level as 2005 as part of the
negotiation of his new employment agreement based on our
analysis of competitive market practice. Mr. Donnan was
promoted to his current position in 2005 and received a base
salary increase at that time. In April 2006, each of
Messrs. Barneson and Maddox received a base salary increase
so that his salary level would be better aligned with the
compensation structure that was being developed in contemplation
of our emergence from chapter 11 bankruptcy.
Mr. Shiba, who resigned effective January 23, 2006,
did not receive a
88
Management
base salary increase in 2006. The base salary of
Mr. Bellino, who joined us in May 2006, was negotiated
based on our analysis of competitive market practice information
provided by our outside compensation consultant. Base salaries
for our named executive officers in 2006 were as follows:
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|
Amount of base | |
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|
salary increase | |
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Name |
|
for 2006 | |
|
2006 Base salary | |
| |
Jack A. Hockema
|
|
|
|
|
|
$ |
730,000 |
|
Joseph P. Bellino
|
|
|
|
|
|
$ |
350,000 |
|
John Barneson
|
|
$ |
5,000 |
|
|
$ |
280,000 |
|
John M. Donnan
|
|
|
|
|
|
$ |
260,000 |
|
Daniel D. Maddox
|
|
$ |
25,000 |
|
|
$ |
225,000 |
|
Kerry A. Shiba
|
|
|
|
|
|
$ |
270,000 |
|
Annual cash incentives
Our annual cash incentives link the compensation of participants
directly to the accomplishment of specific business goals, as
well as individual performance. Annual cash incentive
compensation is intended to focus and reward individuals based
on measures identified as having a positive impact on our annual
business results. Our 2006 Short-Term Incentive Plan, a
transition program based on historical programs using return on
net assets and core cash flows, was designed to (i) focus
attention on earnings before interest, taxes, depreciation and
amortization, or EBITDA, from the fabricated products business
unit in order to continue to tie compensation to returns on net
assets and core cash flows, with modifiers for achievement of
plan, individual performance and safety performance,
(ii) reward achievement of aggressive performance goals,
(iii) provide incentive opportunities consistent with those
provided by companies in the compensation peer group, and
(iv) link performance compensation to individual
performance as well as our ability to pay. Average performance
is not rewarded. When establishing our threshold performance
incentive targets, the compensation committee reviews and
discusses with both senior management and the full board of
directors our business plan and its key underlying assumptions,
expectations under then-existing and anticipated market
conditions and the opportunity to generate stockholder value and
then establishes the performance thresholds and targets for the
year.
During 2006, we made nominal adjustments to the annual cash
incentive targets for each of our named executive officers
(other than Mr. Bellino and Mr. Shiba) based on our
analysis of competitive market practice information provided by
our outside compensation consultant. The annual cash incentive
target of Mr. Bellino, who joined us in May 2006, was
negotiated as part of his employment agreement and based on
competitive market practice at that time. Mr. Shiba, who
resigned effective January 23, 2006, did not participate in
the 2006 Short-Term Incentive Plan. The table below sets forth
the approximate payouts, stated as a percentage of base salary,
that can be earned by our named executive officers (other than
Mr. Shiba), under our 2006 Short-Term Incentive Plan at
each performance level.
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Below | |
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|
Name |
|
threshold | |
|
Threshold | |
|
Target | |
|
Maximum | |
| |
Jack A. Hockema
|
|
|
0% |
|
|
|
34.25% |
|
|
|
68.50% |
|
|
|
205.50% |
|
Joseph P. Bellino
|
|
|
0% |
|
|
|
25.00% |
|
|
|
50.00% |
|
|
|
150.00% |
|
John Barneson
|
|
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0% |
|
|
|
22.50% |
|
|
|
45.00% |
|
|
|
135.00% |
|
John M. Donnan
|
|
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0% |
|
|
|
22.50% |
|
|
|
45.00% |
|
|
|
135.00% |
|
Daniel D. Maddox
|
|
|
0% |
|
|
|
16.67% |
|
|
|
33.33% |
|
|
|
100.00% |
|
A monetary incentive target for each participant is established
for annual cash incentive compensation based on a percentage of
base salary (generally determined based on the 50th percentile
of our
89
Management
compensation peer group, internal compensation balance and
position responsibilities). The monetary incentive targets are
generally set at the beginning of each annual performance
period. For determining compensation under the 2006 Short-Term
Incentive Plan, EBITDA will be determined in March 2007 based on
our 2006 results subject to any adjustments approved by the
compensation committee. These adjustments may spread
extraordinary items over a period of years based upon the
recommendation of our chief executive officer and the approval
of the compensation committee. The resulting award multiple may
then be adjusted within a range of plus or minus 10 percent
based upon fabricated products safety performance.
Each participants base award is determined by multiplying
his or her monetary incentive target by the award multiple.
Based on the fabricated products EBITDA and safety performance,
as well as business unit and individual performance, a
participants monetary award can be modified, in the
aggregate, up to plus or minus 100 percent of the incentive
target or base award (as set forth in the table above for our
named executive officers), subject to an overall cap on the
aggregate award of three times target. A cash pool is
established based upon the award multiple multiplied by the sum
of individual monetary incentive targets for all plan
participants. Although individual monetary awards may be
adjusted up or down, the entire cash pool is paid to
participants. While 2006 results are not yet available, based on
our results through the third quarter, we currently estimate the
2006 award multiple to be between 1.5 to 2.5 of the target
percentage or base award.
Long-term incentives
Upon our emergence from chapter 11 bankruptcy in July 2006,
our Chapter 11 Long-Term Incentive Plan adopted in 2002 as
part of the Chapter 11 KERP terminated and
Messrs. Hockema, Bellino, Barneson, Donnan and Maddox each
received an emergence grant of restricted stock
under our 2006 Equity and Performance Incentive Plan (which we
refer to as our Equity Incentive Plan). We determined that the
emergence grants to senior management were appropriate since our
primary concerns upon emergence were to retain senior
management, including the named executive officers (other than
Mr. Shiba), and to immediately align the interests of
senior management with the interests of our stockholders. We
also wanted to recognize and reward the commitment and efforts
of members of senior management through the four and one-half
years we were in chapter 11 bankruptcy and their ability
during that period to both grow our fabricated products business
and complete a restructuring that allowed us to emerge with a
strong balance sheet and platform for future growth. We
accomplished our objectives by providing stock ownership of
approximately two percent of the outstanding common stock in the
aggregate to members of senior management.
The size of the emergence grants was developed based on
extensive data provided by our outside compensation consultant
on emergence grant practices at other companies emerging from
chapter 11 bankruptcy. Mr. Bellino, who joined us in
May 2006, did not receive an emergence grant but did
receive a grant of shares of restricted stock under the Equity
Incentive Plan based on an analysis of competitive market
practice for a normal annual grant and the terms of his
employment agreement. Mr. Shiba, who resigned effective
January 23, 2006, did not receive a grant of restricted
stock under
90
Management
the Equity Incentive Plan. The table below summarizes the grants
made to our named executive officers (other than Mr. Shiba)
under the Equity Incentive Plan in July 2006:
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|
Percentage of | |
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|
Number of shares | |
|
outstanding | |
Name |
|
restricted stock | |
|
shares | |
| |
Jack A. Hockema
|
|
|
185,000 |
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|
|
.90% |
|
Joseph P. Bellino
|
|
|
15,000 |
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|
|
.07% |
|
John Barneson
|
|
|
48,000 |
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|
|
.23% |
|
John M. Donnan
|
|
|
45,000 |
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|
|
.22% |
|
Daniel D. Maddox
|
|
|
11,334 |
|
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|
.06% |
|
Recognizing that our business is cyclical and that the market
value of the common stock may fluctuate during business cycles,
we also intended the grants to provide an incentive for the
named executive officers and other members of senior management
to remain with us throughout business cycles. Through the
issuance of restricted stock with three-year cliff
vesting to our named executive officers and other members of
senior management, the recipients do not become unconditionally
entitled to receive any of those shares until July 6, 2009,
subject to certain exceptions related to the termination of
employment. Finally, while we view the emergence grants as a
one-time event, we will take the emergence grants into account
in the design of future programs and awards.
We have not yet determined the form of long-term incentive
compensation that we will use in 2007, the form of grants
(i.e., whether it will consist of restricted stock, stock
options, performance shares or other equity-based awards) or the
applicable performance thresholds. That work is ongoing and,
similar to the process we follow to establish annual cash
incentives, includes discussions between the compensation
committee and our outside compensation consultant with respect
to the design and terms of the grants, as well as discussions
between and among the compensation committee, senior management
and the full board of directors with respect to the design and
terms of the grants and our performance and compensation
objectives over the long-term period. For each of
Messrs. Hockema and Bellino, the target cash economic value
of his annual long-term award starting in 2007 was negotiated as
part of his employment agreement and based on competitive market
practice. As part of the negotiation of Mr. Hockemas
agreement, the target cash economic value of his annual
long-term incentive was reduced from approximately
$1.5 million to $1.2 million.
As indicated below, each of the named executive officers (other
than Mr. Bellino, who joined us in May 2006) received
payments under our Chapter 11 Long-Term Incentive Plan. The
Chapter 11 Long-Term Incentive Plan, which is described in
more detail below, terminated upon our emergence from
chapter 11 bankruptcy. Under the Chapter 11 Long-Term
Incentive Plan, key management employees, including
Messrs. Hockema, Barneson, Donnan, Maddox and Shiba, were
eligible to receive an annual cash award based on sustained cost
reductions above $80 million annually for the four and
one-half year period from 2002 through emergence. Awards accrued
on an annual basis during this period in a range between
approximately (16%) to 81% of target, with an average accrual of
approximately 55% of target over the four and one-half year
period. Because the Chapter 11 Long-Term Incentive Plan was
based on sustained cost reductions and continuation of
employment through emergence, no amounts were paid or payable to
the named executive officers until emergence. At emergence, each
of Messrs. Hockema, Barneson, Donnan and Maddox received
approximately one-half of his award, with the remaining portion
of the award payable in a lump sum on July 6, 2007 unless
his employment is terminated by us for cause or voluntarily
terminated by him prior to that date. Mr. Shiba, who
resigned effective January 23, 2006, received his total
award in early 2006 pursuant to the terms of a release entered
into between him and us in connection with his resignation.
91
Management
Stock ownership guidelines
Stock ownership guidelines were introduced upon our emergence
from chapter 11 bankruptcy in July 2006, as part of our
comprehensive compensation structure, in order to further align
the interests of senior management, including the named
executive officers, with those of our stockholders. Under the
guidelines, members of our senior management are expected to
hold common stock having a value equal to a multiple of their
base salary as determined by their position. The guidelines
contemplate a multiple of five times base salary for
Mr. Hockema, and three times base salary for the other
named executive officers. Each member of senior management
covered by our stock ownership guidelines is expected to retain
at least 75 percent of the net shares resulting from equity
compensation awards until he or she achieves the applicable
ownership level contemplated by the stock ownership guidelines.
For purposes of these guidelines, stock ownership includes
shares over which the holder has direct or indirect ownership or
control, including restricted stock and restricted stock units,
but does not include unexercised stock options. The ownership
guidelines are expected to be met within five years. The
compensation committee reviews compliance with the guidelines on
an annual basis. Based on the grants of restricted stock in July
2006 and the reported closing price for our common stock on the
Nasdaq Global Market on December 29, 2006, each named
executive officer owns common stock above the applicable stock
ownership requirements under the stock ownership guidelines.
Retirement benefits
We no longer maintain a defined benefit pension plan or retiree
medical program that covers members of senior management.
Retirement benefits to our senior management, including the
named executive officers, are currently provided through two
principal plans: (1) the Kaiser Aluminum Savings and
Investment Plan,
a tax-qualified
profit-sharing and 401(k) plan (which we refer to as our Savings
Plan), and (2) a nonqualified, unfunded and unsecured
deferred compensation plan (which we refer to as our New
Restoration Plan) intended to restore benefits that would be
payable to participants in the Savings Plan but for the
limitations on benefit accruals and payments imposed by the
Internal Revenue Code. Each of these plans is discussed more
fully below. Although these plans provide reduced benefits to
members of senior management when compared to the benefits
available prior to and during our chapter 11 bankruptcy, we
believe that they support the objectives of our
post-emergence
comprehensive compensation structure, including the ability to
attract and retain senior and experienced mid- to late-career
executives for critical positions within our organization.
In April 2005, we implemented a new defined contribution
retirement program for salaried employees, to be effective as of
May 1, 2005. The program was intended to replace our Old
Pension Plan, which was terminated by the Pension Benefit
Guaranty Corporation, or PBGC, on December 17, 2003, but
with lower costs and risks to us and reduced benefits to the
participants. The new defined contribution retirement program
has three primary components, which are discussed more fully
below: (1) a company match of the employees pre-tax
deferrals under our Savings Plan; (2) a company
contribution to the employees account under our Savings
Plan; and (3) a company contribution to the employees
account under the New Restoration Plan. A decision with respect
to the implementation of the third component was deferred for
consideration by the post-emergence board of directors in the
context of the implementation of our post-emergence
comprehensive compensation structure. Our New Restoration Plan
was adopted upon emergence from chapter 11 bankruptcy.
The implementation of the New Restoration Plan included the
transfer, rather than distribution (as had been contemplated by
the Chapter 11 KERP), of the lump-sum equivalent of the
accrued benefits for the remaining participants under the Old
Restoration Plan into the New Restoration Plan. The table below
summarizes the balances that were transferred into the New
Restoration Plan from the Old Restoration Plan for
Messrs. Hockema, Barneson, Donnan and Maddox.
Mr. Shiba, who resigned effective January 23, 2006,
and Mr. Bellino, who joined us in May 2006, did not
participate in the New Restoration Plan in 2006.
92
Management
|
|
|
|
|
Balance transferred |
|
|
to the New |
Name |
|
Restoration Plan |
|
Jack A. Hockema
|
|
$964,718 |
John Barneson
|
|
$887,366 |
John M. Donnan
|
|
$54,851 |
Daniel D. Maddox
|
|
$41,416 |
Under the terms of the New Restoration Plan, these balances were
transferred to a rabbi trust where they remain
subject to the claims of our creditors and are otherwise
invested in funds designated by each individual from a menu of
possible investments.
Perquisites
During 2006, all of our named executive officers received a
vehicle allowance and all (except Messrs. Donnan and
Maddox) were reimbursed for admission to, and the dues for, a
club membership. Additionally, we reimbursed the legal fees and
expenses incurred by Mr. Hockema in connection with the
negotiation and consummation of his employment agreement and the
housing and other expenses incurred by Mr. Bellino in
connection with his relocation to California upon joining us.
Our use of perquisites as an element of compensation is limited
and is largely based on historical practices and policies of our
company. We do not view perquisites as a significant element of
our comprehensive compensation structure but do believe that
they can be used in conjunction with base salary to attract,
motivate and retain individuals in a competitive environment.
Chapter 11 Retention Plan
As part of the Chapter 11 KERP, we also adopted the
Chapter 11 Retention Plan, a retention plan with certain
key employees, including Messrs. Hockema, Barneson, Donnan
and Maddox, which continued through the first two years of our
restructuring. Although the Chapter 11 Retention Plan was
not extended beyond March 31, 2004, portions of the
payments to Messrs. Hockema and Barneson under the
Chapter 11 Retention Plan through that date were withheld
to further enhance the retention aspects of the Chapter 11
KERP. For Messrs. Hockema and Barneson, $730,000 and
$250,000, respectively, of accrued awards payable under the
Chapter 11 Retention Plan were withheld for subsequent
payment. One-half of the withheld amount was paid in a lump sum
in August 2006 following our emergence from chapter 11
bankruptcy. The remaining one-half is expected to be paid in a
lump sum on July 6, 2007, subject to the continued
employment of Messrs. Hockema and Barneson as more fully
discussed below.
Employment contracts, termination of employment arrangements
and change-in-control arrangements
As discussed more fully below, we have entered into employment
agreements with Messrs. Hockema, Bellino and Maddox. Our
decisions to enter into employment agreements and the terms of
those agreements were based on the facts and circumstances at
the time and an analysis of competitive market practice. With
respect to Messrs. Hockema and Bellino, we worked with our
outside compensation consultant and determined that employment
agreements and the negotiated terms of those agreements were
consistent with market practice. We also determined that
entering into an employment agreement with Mr. Hockema was
important to provide an economic incentive for Mr. Hockema
to delay his retirement until at least July 2011, improve our
ability to retain other key members of senior management and
provide assurance to our customers and other stakeholders of the
continuity of senior management for an extended period beyond
our emergence from chapter 11 bankruptcy. With respect to
Mr. Maddox, who lives in Houston, Texas where we were
formerly headquartered and who expressed his desire to remain in
Houston, we determined that it was important to provide an
incentive for Mr. Maddox to remain with our company through
at least
93
Management
March 2007 in order to help facilitate and complete the
transition of our accounting function to our current
headquarters in Foothill Ranch, California and the training of
his replacement. In each case, we determined that the agreements
and the terms of those agreements were in the best interests of
our company and stockholders.
Also, as discussed more fully below, we provide all named
executive officers with benefits related to certain terminations
of employment, including in connection with a change in control,
by us without cause and by the named executive officer with good
reason. These protections for all the named executive officers
(other than Mr. Bellino, who joined us in May 2006 just
prior to our emergence from chapter 11 bankruptcy and,
accordingly, did not participate in the Chapter 11 KERP)
and other members of senior management were supported by our
creditors and approved by the bankruptcy court as part of the
Chapter 11 KERP. Importantly, these protections limit our
ability to downwardly adjust certain aspects of compensation,
including base salaries and target incentive compensation,
without triggering the ability of the affected named executive
officer to receive termination benefits. Mr. Hockemas
protection is now part of his employment agreement, replacing
the similar protection previously available to him under
Chapter 11 KERP agreements. Similarly,
Mr. Bellinos protection is part of his employment
agreement. We view these severance protection benefits as an
important component of the total compensation package for each
of our named executive officers. In our view, having these
protections helps to maintain the named executive officers
objectivity in decision-making and provides another vehicle to
align the interests of our named executive officer with the
interests of our stockholders.
Tax deductibility
Section 162(m) of the Internal Revenue Code limits the
deductibility of compensation in excess of $1 million paid
to our chief executive officer and our four other highest-paid
executive officers unless certain specific and detailed criteria
are satisfied. We believe that it is often desirable and in our
best interests to deduct compensation payable to our executive
officers. In this regard, we consider the anticipated tax
treatment to our company and our executive officers in the
review and establishment of compensation programs and payments.
While no assurance can be given that compensation will be fully
deductible under Section 162(m), we will continue to
evaluate steps that we can take to increase or otherwise
preserve deductibility. In the interim, we have determined that
we will not seek to limit compensation to that deductible under
Section 162(m), particularly in light of the substantial
net operating loss carry-forwards that we expect to be available
to us to offset taxable income.
94
Management
Summary compensation table for 2006
The table below sets forth information regarding 2006
compensation for our named executive officers:
(1) Jack A. Hockema, our President, Chief Executive
Officer and Chairman of the Board; (2) Joseph P.
Bellino, our Executive Vice President and Chief Financial
Officer (who joined us in May 2006); (3) each of John
Barneson, John M. Donnan and Daniel D. Maddox, our
three other most highly compensated executive officers (based on
total compensation for 2006); and (4) Kerry A. Shiba,
our former Vice President and Chief Financial Officer (who
resigned effective January 23, 2006). As indicated below
and more fully explained in footnote 3, the table below does not
reflect earnings under our 2006 Short-Term Incentive Plan.
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Change in | |
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pension | |
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value and | |
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nonqualified | |
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Non-equity | |
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deferred | |
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Name and principal |
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Stock | |
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incentive plan | |
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compensation | |
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All other | |
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position |
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Year |
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Salary |
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awards(1) | |
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compensation(2)(3) | |
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earnings(4) | |
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compensation | |
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Total | |
| |
Jack A. Hockema
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2006 |
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$730,000 |
|
$ |
1,301,167 |
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$ |
1,649,440 |
(5) |
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$ |
8,403 |
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|
$ |
539,556 |
(6)(7)(8)(9) |
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$ |
4,228,566 |
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President, Chief Executive Officer and Chairman of the Board |
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Joseph P. Bellino
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2006 |
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$220,018 |
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$ |
105,500 |
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(5) |
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|
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$ |
39,119 |
(6)(7)(10) |
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$ |
364,637 |
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Executive Vice President and Chief Financial Officer |
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John Barneson
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2006 |
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$278,750 |
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$ |
337,600 |
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|
$ |
346,938 |
(5) |
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$ |
5,020 |
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|
$ |
191,942 |
(6)(7)(8)(11) |
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$ |
1,160,250 |
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Senior Vice President and Chief Administrative Officer |
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John M. Donnan
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2006 |
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$260,000 |
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$ |
316,500 |
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$ |
104,554 |
(5) |
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$ |
(603 |
) |
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$ |
41,897 |
(6)(7)(12) |
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$ |
722,348 |
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Vice President, Secretary and General Counsel |
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Daniel D. Maddox
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2006 |
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$222,917 |
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$ |
318,863 |
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$ |
114,043 |
(5) |
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$ |
(256 |
) |
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$ |
36,971 |
(6)(7)(13) |
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$ |
692,538 |
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Vice President
and Controller |
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Kerry A. Shiba
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2006 |
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$17,386 |
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$ |
253,511 |
(5) |
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$ |
884 |
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|
$ |
433,646 |
(6)(14) |
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$ |
705,427 |
|
Vice President
and Chief
Financial Officer |
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(1) |
Reflects the value of restricted stock awards granted to our
named executive officers under our Equity Incentive Plan on
July 6, 2006 in connection with our emergence from
chapter 11 bankruptcy based on the compensation cost of the
award with respect to our 2006 fiscal year computed in
accordance with Financial Accounting Standards Board Statement
of Financial Accounting Standards No. 123 (revised 2004),
Share-Based Payment, which we refer to as
SFAS No. 123-R,
but excluding any impact of assumed forfeiture rates. The number
of shares of restricted stock received by our named executive
officers pursuant to such awards was as follows:
Mr. Hockema, 185,000; Mr. Bellino, 15,000;
Mr. Barneson, 48,000; Mr. Donnan, 45,000; and
Mr. Maddox, 11,334. The table reflects the expense
recognized for each named |
95
Management
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executive officer (other than Messrs. Maddox and Shiba)
for the six-month portion of the three-year vesting period for
the restricted stock extending from our emergence date through
December 31, 2006, computed in accordance with SFAS
No. 123-R, but excluding any impact of assumed forfeiture
rates, based on (a) a per share value at emergence of
$42.20 and (b) the total number of shares of restricted
stock received by the named executive officer. The table
reflects the expense recognized for Mr. Maddox computed in
accordance with SFAS No. 123-R, but excluding any impact of
assumed forfeiture rates, based on (a) a per share value at
emergence of $42.20, (b) the total number of shares of
restricted stock received by him, (c) the assumptions that
his employment will terminate and that his shares of restricted
stock will vest on March 31, 2007, and (d) the six-
month portion of the assumed nine-month vesting period for his
restricted stock extending from our emergence date through
December 31, 2006. Mr. Shiba, who resigned effective
January 23, 2006, did not receive a restricted stock
award. |
|
(2) |
Reflects payments under our Chapter 11 Long-Term
Incentive Plan, pursuant to which key management employees
accrued cash awards based on our attainment of sustained cost
reductions above $80 million annually for the four and
one-half year period from 2002 through our emergence from
chapter 11 bankruptcy on July 6, 2006. |
|
(3) |
Does not reflect earnings under our 2006 Short-Term Incentive
Plan, pursuant to which key management employees earned cash
awards based on the financial and safety performance of our
fabricated products business unit, the performance of the
particular business unit to which the employee was assigned and
individual performance objectives, because earnings under our
2006 Short-Term Incentive Plan are not presently calculable.
Amounts earned by Messrs. Hockema, Bellino, Barneson,
Donnan and Maddox under our 2006 Short-Term Incentive Plan are
expected to be determined in March 2007, at which time they will
be disclosed by us in a Current Report on
Form 8-K filed
with the SEC. As indicated above, although 2006 results are not
yet available, based on our results through the third quarter,
we currently estimate that the 2006 award multiple will be
between 1.5 and 2.5 of the target percentage or award and,
accordingly, that individual awards will be between 1.5 and
2.5 times an individuals incentive target percentage
or award, before taking into account any adjustments for
individual performance and applicable modifiers. Mr. Shiba,
who resigned effective January 23, 2006, did not
participate in our 2006 Short-Term Incentive Plan. |
|
|
(4) |
Reflects the aggregate change in actuarial present value of
the named executive officers accumulated benefit under our
Old Pension Plan during 2006 calculated by (a) assuming
mortality according to the
RP-2000 Combined Health
mortality table published by the Society of Actuaries and
(b) applying a discount rate of 5.50% per annum to
determine the actuarial present value of the accumulated benefit
at December 31, 2005 and a discount rate of 5.75% per annum
to determine the actuarial present value of the accumulated
benefit at December 31, 2006. Effective December 17,
2003, the PBGC terminated and effectively assumed responsibility
for making benefit payments in respect of our Old Pension Plan,
whereupon all benefit accruals under the Old Pension Plan ceased
and benefits available thereunder to certain salaried employees,
including Messrs. Hockema and Barneson, were significantly
reduced due to the limitations on benefits payable by the PBGC.
Above-market or preferential earnings are not available under
our New Restoration Plan, which is our only plan or arrangement
pursuant to which compensation may be deferred on a basis that
is not tax-qualified, or any of our other benefit plans. |
|
|
(5) |
Reflects amounts paid under our Chapter 11 Long-Term
Incentive Plan in 2006. For each of Messrs. Hockema,
Barneson, Donnan and Maddox, these amounts represent
approximately one-half of the total amounts accrued under our
Chapter 11 Long-Term Incentive Plan during the four and
one-half year period from 2002 through our emergence from
chapter 11 bankruptcy on July 6, 2006; for
Mr. Shiba, the amount represents the total amount accrued.
The total amounts accrued under our Chapter 11 Long-Term
Incentive Plan during the four and one-half year period for
Messrs. Hockema, Barneson, Donnan and Maddox were as
follows: Mr. Hockema, $3,298,880; Mr. Barneson,
$693,876; Mr. Donnan, $208,575; and Mr. Maddox,
$227,228. |
(footnotes continued on following page)
96
Management
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|
Individual amounts accrued by year for Messrs. Hockema,
Barneson, Donnan and Maddox were as follows: Mr. Hockema,
$2,324,557 in 2002 and 2003, $918,818 in 2004, ($240,819) in
2005 and $296,324 in 2006; Mr. Barneson, $466,534 in 2002
and 2003, $214,391 in 2004, ($56,191) in 2005 and $69,142 in
2006; Mr. Donnan, $146,045 in 2002 and 2003, $55,129 in
2004, ($32,109) in 2005 and $39,510 in 2006; and
Mr. Maddox, $162,274 in 2002 and 2003, $61,255 in 2004,
($16,055) in 2005 and $19,755 in 2006. Annual awards during this
period were approximately 81% of target in 2002 and 2003; 61% of
target in 2004; (16%) of target in 2005; and 40% of target in
2006, with an average award of approximately 55% of target over
the four and one-half year period. For each of
Messrs. Hockema, Barneson, Donnan and Maddox, the 2006
payments under our Chapter 11 Long-Term Incentive Plan were
made in August 2006 following our emergence and the remaining
portion of the total amount (subject to adjustment in accordance
with the terms of the Chapter 11 Long-Term Incentive Plan)
will be paid on July 6, 2007 unless he is terminated for
cause or voluntarily terminates his employment prior to that
date. For Mr. Shiba, pursuant to the terms of a release
entered into between him and us in connection with his
resignation, the total was paid in early 2006. Mr. Bellino,
who joined us in May 2006, did not participate in our
Chapter 11 Long-Term Incentive Plan. |
|
(6) |
Includes contributions made by us under our Savings Plan, as
follows: Mr. Hockema, $22,883; Mr. Barneson, $24,225;
Mr. Donnan, $21,133; and Mr. Maddox, $20,240. We did not
make contributions under our Savings Plan to Mr. Shiba, who
resigned effective January 23, 2006, or Mr. Bellino,
who joined us in May 2006. |
|
(7) |
Includes contributions made by us under our New Restoration
Plan which is intended to restore the benefit of contributions
that we would have otherwise paid to participants under our
Savings Plan but for limitations imposed by the Internal Revenue
Code, as follows: Mr. Hockema, $105,037; Mr. Barneson,
$27,873; Mr. Donnan, $9,809; and Mr. Maddox, $5,579.
Mr. Shiba, who resigned effective January 23, 2006, and
Mr. Bellino, who joined us in May 2006, did not participate
in our New Restoration Plan. |
|
(8) |
Includes amounts paid to Messrs. Hockema and Barneson
under our Chapter 11 Retention Plan in 2006 as follows:
Mr. Hockema, $365,000; and Mr. Barneson, $125,000. For each
of Messrs. Hockema and Barneson, these amounts represent
approximately one-half of the total retention payments withheld
from Messrs. Hockema and Barneson under the Chapter 11
Retention Plan. The total amounts withheld from
Messrs. Hockema and Barneson were as follows:
Mr. Hockema, $730,000; and Mr. Barneson, $250,000. The
2006 payments under our Chapter 11 Retention Plan were made
in August 2006 following our emergence from chapter 11
bankruptcy and the remaining portion of the total amount
withheld from each of Messrs. Hockema and Barneson will be
paid on July 6, 2007 unless he is terminated for cause or
voluntarily terminates his employment prior to that date. |
|
(9) |
Includes the cost to us of perquisites and other personal
benefits for Mr. Hockema as follows: club membership dues,
$6,875; legal fees and expenses incurred by Mr. Hockema in
connection with the negotiation and consummation of his
employment agreement with us, $25,191; and vehicle allowance,
$14,570. |
|
|
(10) |
Includes the cost to us of perquisites and other personal
benefits for Mr. Bellino as follows: club membership dues,
$3,040; housing and other expenses associated with his
relocation to California, $27,840; and vehicle allowance,
$8,239. |
|
(11) |
Includes the cost to us of perquisites and other personal
benefits for Mr. Barneson as follows: club membership dues,
$4,385; and vehicle allowance, $10,459. |
|
(12) |
Includes the cost to us of perquisites and other personal
benefits for Mr. Donnan as follows: vehicle allowance,
$10,955. |
|
(13) |
Includes the cost to us of perquisites and other benefits for
Mr. Maddox as follows: vehicle allowance, $11,152. |
|
(14) |
Includes $431,777 paid or accrued to Mr. Shiba pursuant
to the release entered into between him and us in connection
with his resignation (exclusive of amounts earned by him under
our Chapter 11 Long-Term Incentive Plan (see Note 4
above) and amounts referred to in the next |
97
Management
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|
sentence). Also includes the cost to us of perquisites and
other personal benefits for Mr. Shiba as follows: club
membership dues, $1,210; and vehicle allowance, $659. |
As reflected in the table above, the salary received by each of
our named executive officers as a percentage of their respective
total compensation during 2006 was as follows: Mr. Hockema,
17.3%; Mr. Bellino (who joined us in May 2006), 60.3%;
Mr. Barneson, 24.0%; Mr. Donnan, 36.0%;
Mr. Maddox, 32.2%; and Mr. Shiba (who resigned
effective January 23, 2006), 2.5%.
Grants of plan-based awards in 2006
The table below sets forth information regarding grants of
plan-based awards made to our named executive officers during
2006.
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Estimated future payouts under | |
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All other stock | |
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non-equity incentive plan awards(1) | |
|
awards: number | |
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Grant date fair | |
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| |
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of shares of | |
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value of stock | |
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Threshold | |
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Target | |
|
Maximum | |
|
stock or units(2) | |
|
awards(3) | |
Name |
|
Grant date | |
|
($) | |
|
($) | |
|
($) | |
|
(#) | |
|
($) | |
| |
Jack A. Hockema
|
|
|
|
|
|
$ |
250,025 |
|
|
$ |
500,050 |
|
|
$ |
1,500,150 |
|
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|
7/6/06 |
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185,000 |
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$ |
7,807,000 |
|
Joseph P. Bellino
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$ |
87,500 |
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$ |
175,000 |
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$ |
525,000 |
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|
7/6/06 |
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|
15,000 |
|
|
$ |
633,000 |
|
John Barneson
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$ |
63,000 |
|
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$ |
126,000 |
|
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$ |
378,000 |
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|
7/6/06 |
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|
48,000 |
|
|
$ |
2,025,600 |
|
John M. Donnan
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|
$ |
58,500 |
|
|
$ |
117,000 |
|
|
$ |
351,000 |
|
|
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|
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|
7/6/06 |
|
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|
|
|
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|
45,000 |
|
|
$ |
1,899,000 |
|
Daniel D. Maddox
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|
|
|
|
|
$ |
37,500 |
|
|
$ |
75,000 |
|
|
$ |
225,000 |
|
|
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|
7/6/06 |
|
|
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|
|
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|
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|
11,334 |
|
|
$ |
478,295 |
|
Kerry A. Shiba
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(1) |
Reflects the threshold, target and maximum award amounts
under our 2006 Short-Term Incentive Plan for our named executive
officers. No awards are available below the threshold
performance level. Mr. Shiba, who resigned effective
January 23, 2006, did not participate in our 2006
Short-Term Incentive Plan. Under our 2006 Short-Term Incentive
Plan, participants may receive a cash incentive award between
one-half and three times the participants target award
amount. As indicated above, although 2006 results are not yet
available, based on our results through the third quarter, we
currently estimate that the 2006 award multiple will be between
1.5 and 2.5 of the target percentage or award and, accordingly,
that individual awards will be between 1.5 and 2.5 times an
individuals incentive target percentage or award, before
taking into account any adjustments for individual performance
and applicable modifiers. |
|
(2) |
Reflects the number of shares of restricted stock received by
our named executive officers pursuant to awards granted under
our Equity Incentive Plan on July 6, 2006 in connection
with our emergence from chapter 11 bankruptcy. The
restrictions on all such shares will lapse on July 6, 2009
or earlier if the named executive officers employment
terminates as a result of death or disability, the named
executive officers employment is terminated by us without
cause, the named executive officers employment is
voluntarily terminated by him for good reason or if there is a
change in control or, in the case of Mr. Maddox, his
employment is terminated (other than by us for cause) upon the
conclusion of his employment agreement. Mr. Shiba, who
resigned effective January 23, 2006, did not receive a
restricted stock award. |
(footnotes continued on following page)
98
Management
|
|
(3) |
The grant date fair value of the restricted stock awards
reflected in this table is computed in accordance with SFAS
No. 123-R, but excluding any impact of assumed forfeiture
rates, based on (a) a per share value at our emergence from
chapter 11 bankruptcy of $42.20 and (b) the total number of
shares of restricted stock awarded. |
Employment-related agreements and certain employee benefit
plans
Employment agreement with Jack A. Hockema
On July 6, 2006, in connection with our emergence from
chapter 11 bankruptcy, we entered into an employment
agreement with Jack A. Hockema, pursuant to which
Mr. Hockema continued his duties as our President and Chief
Executive Officer. Under the terms of his employment agreement,
Mr. Hockemas initial base salary is $730,000 and his
annual short-term incentive target under our 2006 Short-Term
Incentive Plan is equal to 68.5% of his base salary. The
short-term incentive is payable in cash, but is subject to both
our meeting the applicable underlying performance thresholds and
an annual cap of three times the target. If
Mr. Hockemas employment terminates other than on a
date which is the last day of a fiscal year, then his annual
short-term incentive target with respect to the fiscal year in
which his employment terminates will be prorated for the actual
number of days of employment during such fiscal year, and such
amount will be paid to Mr. Hockema or his estate unless his
employment was terminated by us for cause or was voluntarily
terminated by him without good reason. Under the employment
agreement, Mr. Hockema received a grant of 185,000 shares
of restricted stock on July 6, 2006 under our Equity
Incentive Plan; the restrictions on all such shares will lapse
on July 6, 2009 or earlier if his employment is terminated
as a result of his death, disability or retirement, his
employment is terminated by us without cause or his employment
is voluntarily terminated by him with good reason, or if there
is a change in control. Starting in 2007, he will be entitled to
receive annual equity awards (such as restricted stock, stock
options or performance shares) with a target cash economic value
of 165% of his base salary; the terms of all equity grants to
Mr. Hockema will be similar to the terms of equity grants
made to other senior executives at the time they are made,
except that the grants must provide for full vesting at
retirement and pro rata vesting upon any other termination of
his employment except termination by us for cause or voluntary
termination by him without good reason. The initial term of his
employment agreement is five years and it will be automatically
renewed and extended for one-year periods unless either party
provides notice one year prior to the end of the initial term or
any extension period. Mr. Hockema also participates in the
various benefit plans for salaried employees.
Under Mr. Hockemas employment agreement, following
any termination of his employment, we must pay or provide to
Mr. Hockema or his estate:
|
|
|
base salary earned through the
date of such termination;
|
|
|
except in the case of a
termination by us for cause or by him other than for good
reason, earned but unpaid incentive awards;
|
|
|
accrued but unpaid vacation;
|
|
|
benefits under our employment
benefit plans to the extent vested and not forfeited on the date
of such termination; and
|
|
|
benefit continuation and
conversion rights to the extent provided under our employment
benefit plans.
|
In addition, if Mr. Hockemas employment is terminated
as a result of his death or disability, all of his outstanding
equity awards will vest in accordance with their terms, subject
to the provisions described above, and all of his vested but
unexercised grants will remain exercisable through the second
anniversary of such termination. If Mr. Hockemas
employment is terminated by us for cause or is
99
Management
voluntarily terminated by him without good reason, all of his
unvested equity grants will be forfeited and all of his vested
but unexercised equity grants will be forfeited on the date that
is 90 days following such termination. If
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him with good reason, in
addition to the payment of his accrued benefits as described
above, (1) we will make a lump-sum payment to
Mr. Hockema in an amount equal to two times the sum of his
base salary and annual short-term incentive target, (2) his
medical, dental, vision, life insurance and disability benefits,
which we refer to as welfare benefits, will continue for two
years commencing on the date of such termination, and
(3) all of his outstanding equity awards will vest in
accordance with their terms, subject to the provisions described
above, and all of his vested but unexercised grants will remain
exercisable through the second anniversary of such termination.
If there is a change in control of our company, all of
Mr. Hockemas equity awards outstanding as of the date
of such change in control will fully vest. If
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him with good reason
within two years following a change in control, in addition to
the payments of his accrued benefits as described above,
(1) we will make a lump-sum payment to Mr. Hockema in
an amount equal to three times the sum of his base salary and
annual short-term incentive target, (2) his welfare
benefits will continue for three years commencing on the date of
such termination, and (3) all previously unvested equity
grants will become exercisable and vested but unexercisable
grants will remain exercisable through the second anniversary of
such termination. If any payments to Mr. Hockema would be
subject to federal excise tax by reason of being considered
contingent on a change in control, we must pay to
Mr. Hockema an additional amount such that, after
satisfaction of all tax obligations imposed on such payments,
Mr. Hockema retains an amount equal to such federal excise
tax.
Mr. Hockema will be subject to noncompetition,
nonsolicitation and confidentiality restrictions following his
termination of employment.
For quantitative disclosure regarding estimated payments and
other benefits that would have been received by Mr. Hockema
or his estate if his employment had terminated on
December 29, 2006, the last business day of 2006, under
various circumstances, see Potential payments
and benefits upon termination of employment.
Employment agreement with Joseph P. Bellino
On July 6, 2006, in connection with our emergence from
chapter 11 bankruptcy, we entered into an employment
agreement with Joseph P. Bellino, pursuant to which
Mr. Bellino continued his duties as our Executive Vice
President and Chief Financial Officer. The agreement supersedes
an employment agreement with Mr. Bellino that was entered
into when he joined us in May 2006. Under the terms of his
employment agreement, Mr. Bellinos initial base
salary is $350,000 and his annual short-term incentive target
under our 2006 Short-Term Incentive Plan is equal to 50% of his
base salary. The short-term incentive is payable in cash, but is
subject to both our meeting the applicable underlying
performance thresholds and an annual cap of three times the
target. If Mr. Bellinos employment terminates other
than on a date which is the last day of a fiscal year, then his
annual short-term incentive target with respect to the fiscal
year in which his employment terminates will be prorated for the
actual number of days of employment during such fiscal year, and
such amount will be paid to Mr. Bellino or his estate
unless his employment was terminated by us for cause or was
voluntarily terminated by him without good reason. Under the
employment agreement, Mr. Bellino received an initial grant
of 15,000 shares of restricted stock on July 6, 2006 under
our Equity Incentive Plan; the restrictions on all such shares
will lapse on July 6, 2009 or earlier if his employment is
terminated as a result of his death, disability or retirement,
his employment is terminated by us without cause or his
employment is voluntarily terminated by him with good reason, or
if there is a change in control. Starting in 2007, he will be
entitled to receive annual equity awards (such as restricted
stock, stock
100
Management
options or performance shares) with a target cash economic value
of $450,000; the terms of all equity grants will be similar to
the terms of equity grants made to other senior executives at
the time they are made. The initial term of his employment
agreement is through May 15, 2009 and will be automatically
renewed and extended for one-year periods unless either party
provides notice one year prior to the end of the initial term or
any extension period. Mr. Bellino also participates in the
various benefit plans for salaried employees.
Under Mr. Bellinos employment agreement, following
any termination of his employment, we must pay or provide to
Mr. Bellino or his estate:
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base salary earned through the
date of such termination;
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except in the case of a
termination by us for cause or by him other than for good
reason, earned but unpaid incentive awards;
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accrued but unpaid vacation;
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benefits under our employment
benefit plans to the extent vested and not forfeited on the date
of such termination; and
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benefit continuation and
conversion rights to the extent provided under our employment
benefit plans.
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In addition, if Mr. Bellinos employment is terminated
as a result of his death or disability, all of his outstanding
equity awards will vest in accordance with their terms, subject
to the provisions described above, and all of his vested but
unexercised grants will remain exercisable through the second
anniversary of such termination. If Mr. Bellinos
employment is terminated by us for cause or is voluntarily
terminated by him without good reason, all of his unvested
equity grants will be forfeited and all of his vested but
unexercised equity grants will be forfeited on the date that is
90 days following such termination. If
Mr. Bellinos employment is terminated by us without
cause or is voluntarily terminated by him with good reason, in
addition to the payment of his accrued benefits as described
above, (1) we will make a lump-sum payment to
Mr. Bellino in an amount equal to two times the sum of his
base salary and annual short-term incentive target, (2) his
welfare benefits will continue for two years commencing on the
date of such termination, and (3) all of his outstanding
equity awards will vest in accordance with their terms, subject
to the provisions described above, and all of his vested but
unexercised grants will remain exercisable through the second
anniversary of such termination.
If there is a change in control of our company, all of
Mr. Bellinos equity awards outstanding as of the date
of such change in control will fully vest. If
Mr. Bellinos employment is terminated by us without
cause or is voluntarily terminated by him with good reason
within two years following a change in control, in addition to
the payments of his accrued benefits as described above,
(1) we will make a lump-sum payment to Mr. Bellino in
an amount equal to three times the sum of his base salary and
annual short-term incentive target, (2) his welfare
benefits will continue for three years commencing on the date of
such termination, and (3) all previously unvested equity
grants will become exercisable and vested but unexercisable
grants will remain exercisable through the second anniversary of
such termination. If any payments to Mr. Bellino would be
subject to federal excise tax by reason of being considered
contingent on a change in control, we must pay to
Mr. Bellino an additional amount such that, after
satisfaction of all tax obligations imposed on such payments,
Mr. Bellino retains an amount equal to such federal excise
tax.
Mr. Bellino will be subject to noncompetition,
nonsolicitation and confidentiality restrictions following his
termination of employment.
For quantitative disclosure regarding estimated payments and
other benefits that would have been received by Mr. Bellino
or his estate if his employment had terminated on
December 29, 2006, the last
101
Management
business day of 2006, under various circumstances, see
Potential payments and benefits upon
termination of employment.
Employment agreement with Daniel D. Maddox
On July 6, 2006, in connection with our emergence from
chapter 11 bankruptcy, we entered into an employment
agreement with Daniel D. Maddox, pursuant to which
Mr. Maddox continued his duties as our Vice President and
Controller. Under the terms of his employment agreement,
Mr. Maddoxs initial base salary is $225,000 and his
annual short-term incentive target under our 2006 Short-Term
Incentive Plan is equal to $75,000, subject to being prorated
for partial years. The short-term incentive is payable in cash,
but is subject to our meeting the applicable underlying
performance thresholds. Under the employment agreement,
Mr. Maddox received an initial grant of 11,334 shares of
restricted stock on July 6, 2006 under our Equity Incentive
Plan; the terms of the restricted stock grant to Mr. Maddox
are similar to the terms of restricted stock grants made to
other senior executives on July 6, 2006. The term of his
employment agreement continues until the earlier of a mutually
agreed upon termination date and March 31, 2007. If
Mr. Maddoxs employment is terminated (other than by
death or disability or by us for cause) upon the conclusion of
this agreement, he will receive benefits under his Change in
Control Agreement as if both a change in control had occurred
prior to his departure and he was terminating his employment for
good reason. In addition, if Mr. Maddoxs employment
is terminated (other than by us for cause) upon the conclusion
of this agreement, the restrictions on his 11,334 shares of
restricted stock will lapse. Mr. Maddox also participates
in the various retirement and benefit plans for salaried
employees.
For quantitative disclosure regarding payments and other
benefits that would have been received by Mr. Maddox or his
estate if his employment had terminated on December 29,
2006, the last business day of 2006, under various
circumstances, see Potential payments and benefits
upon termination of employment.
Severance Plan
Effective September 3, 2002, in connection with the
commencement of our chapter 11 bankruptcy and the
implementation of the Chapter 11 KERP, we adopted our
Severance Plan to provide selected executive officers, including
Messrs. Hockema, Barneson, Donnan, Maddox and Shiba, and
other key employees with appropriate protection in the event of
certain terminations of employment and entered into severance
agreements with plan participants. Mr. Hockemas
employment agreement discussed above replaces his participation
in the Severance Plan and supersedes his severance agreement.
Mr. Shibas resignation effective January 23,
2006 did not trigger rights under the Severance Plan or his
severance agreement. The Severance Plan and related severance
agreements terminate on July 6, 2007.
Our Severance Plan provides for payment of a severance benefit
and continuation of welfare benefits upon termination of
employment in certain circumstances. Participants are eligible
for the severance payment and continuation of welfare benefits
in the event the participants employment is terminated
without cause or the participant terminates his or her
employment with good reason. The severance payment and
continuation of welfare benefits are not available if:
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the participant receives
severance compensation or welfare benefit continuation pursuant
to a Change in Control Agreement (described below);
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the participants
employment is terminated other than by us without cause or by
the participant for good reason; or
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the participant declines to
sign, or subsequently revokes, a designated form of release.
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102
Management
In consideration for the severance payment and continuation of
welfare benefits, a participant will be subject to
noncompetition, nonsolicitation and confidentiality restrictions
following the participants termination of employment.
The severance payment payable under the Severance Plan to
Messrs. Barneson, Donnan and Maddox consists of a lump-sum
cash payment equal to two times (for Mr. Barneson) or one
time (for Messrs. Donnan and Maddox) their base salaries.
In addition, welfare benefits are continued for a period of two
years (for Mr. Barneson) or one year (for
Messrs. Donnan and Maddox) following termination of
employment.
For quantitative disclosure regarding estimated payments and
other benefits that would have been received by each of
Messrs. Barneson, Donnan and Maddox or his estate if his
employment had terminated on December 29, 2006, the last
business day of 2006, under various circumstances, see
Potential payments and benefits upon
termination of employment.
Change in control severance agreements
In 2002, in connection with the commencement of our
chapter 11 bankruptcy and the implementation of the
Chapter 11 KERP, we also entered into Change in Control
Agreements with certain key executives, including
Messrs. Hockema, Barneson, Donnan, Maddox and Shiba, in
order to provide them with appropriate protection in the event
of a termination of employment in connection with a change in
control or, except as otherwise provided, a significant
restructuring. Mr. Hockemas employment agreement
discussed above supersedes his Change in Control Agreement.
Mr. Shibas resignation effective January 23,
2006 did not trigger rights under his Change in Control
Agreement. The Change in Control Agreements terminate on the
second anniversary of a change in control.
The Change in Control Agreements provide for severance payments
and continuation of welfare benefits upon termination of
employment in certain circumstances. The participants are
eligible for severance benefits if their employment is
terminated by us without cause or by the participant with good
reason during a period that commences 90 days prior to the
change in control and ends on the second anniversary of the
change in control. Participants (including Messrs. Donnan
and Maddox but excluding Mr. Barneson) also are eligible
for severance benefits if their employment is terminated by us
due to a significant restructuring even when there has been no
change in control. These benefits are not available if:
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the participant receives
severance compensation or welfare benefit continuation pursuant
to the Severance Plan or any other prior agreement;
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the participants
employment is terminated other than by us without cause or by
the participant for good reason; or
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|
the participant declines to
sign, or subsequently revokes, a designated form of release.
|
In consideration for the severance payment and continuation of
benefits, a participant will be subject to noncompetition,
nonsolicitation and confidentiality restrictions following his
or her termination of employment with us.
Upon a qualifying termination of employment, each of
Messrs. Barneson, Donnan and Maddox are entitled to receive
the following:
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three times (for
Mr. Barneson) or two times (for Messrs. Donnan and
Maddox) the sum of his base pay and most recent short-term
incentive target;
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a pro-rated portion of his
short-term incentive target for the year of termination; and
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103
Management
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a pro-rated portion of his
long-term incentive target in effect for the year of his
termination, provided that such target was achieved.
|
In addition, welfare benefits and perquisites are continued for
a period of three years (for Mr. Barneson) or two years
(for Messrs. Donnan and Maddox) after termination of
employment with us.
In general, if any payments would be subject to federal excise
tax or any similar state or local tax by reason of being
considered contingent on a change in control, the participant
will be entitled to receive an additional amount such that,
after satisfaction of all tax obligations imposed on such
payments, the participant retains an amount equal to the federal
excise tax or similar state or local tax imposed on such
payments. However, if no such federal excise tax or similar
state or local tax would apply if the aggregate payments were
reduced by 5%, then the aggregate payments to the participant
will be reduced by the amount necessary to avoid application of
such federal excise tax or similar state or local tax.
For quantitative disclosure regarding estimated payments and
other benefits that would have been received by each of
Messrs. Barneson, Donnan and Maddox or his estate if his
employment had terminated on December 29, 2006, the last
business day of 2006, under various circumstances, see
Potential payments and benefits upon
termination of employment.
Release with Kerry A. Shiba
Kerry A. Shiba resigned as our Vice President and Chief
Financial Officer effective January 23, 2006. In connection
with his resignation, we entered into a release with
Mr. Shiba. Pursuant to the terms of the release, in lieu of
all benefits to which Mr. Shiba might otherwise be entitled
and in consideration of his satisfaction of certain
post-termination obligations, Mr. Shiba received payments
of $687,157 in the aggregate, including payments of his earned
awards under our Chapter 11 Long-Term Incentive Plan, his
earned short-term incentive award for 2005 and his accrued
unpaid vacation, payments of COBRA premiums for his medical and
dental coverage and payments in respect of certain perquisites.
The release also provides for a mutual release and subjects
Mr. Shiba to certain noncompetition, nondisclosure and
nonsolicitation obligations.
Equity Incentive Plan
On July 6, 2006, upon our emergence from chapter 11
bankruptcy and the implementation of our plan of reorganization,
our Equity Incentive Plan became effective. The Equity Incentive
Plan is an omnibus plan that facilitates the issuance of future
long-term incentive awards as part of our comprehensive
compensation structure and is administered by a committee of
non-employee directors of our board of directors, currently the
compensation committee.
Our officers and other key employees, as selected by the
compensation committee are eligible to participate in the Equity
Incentive Plan. As of December 31, 2006, approximately
40 officers and other key employees had been selected by
the compensation committee to receive awards under the Equity
Incentive Plan. Our non-employee directors also participate in
the Equity Incentive Plan.
Subject to certain adjustments that may be required from time to
time to prevent dilution or enlargement of the rights of
participants under the Equity Incentive Plan, a maximum of
2,222,222 shares of common stock may be issued under the
Equity Incentive Plan, of which 525,660 shares have been
issued to our directors, officers and key employees and were
outstanding as of December 31, 2006.
Our Equity Incentive Plan permits the granting of awards in the
form of options to purchase our common stock, stock appreciation
rights, shares of restricted stock, restricted stock units,
performance shares, performance units and other awards.
104
Management
The Equity Incentive Plan will expire on July 6, 2016. No
grants will be made under the Equity Incentive Plan after that
date, but all grants made on or prior to such date will continue
in effect thereafter subject to the terms thereof and of the
Equity Incentive Plan.
Our board of directors may, in its discretion, terminate the
Equity Incentive Plan at any time. The termination of the Equity
Incentive Plan would not affect the rights of participants or
their successors under any awards outstanding and not exercised
in full on the date of termination.
The compensation committee may at any time and from time to time
amend the Equity Incentive Plan in whole or in part. Any
amendment which must be approved by our stockholders in order to
comply with applicable law or the rules of the principal
securities exchange, association or quotation system on which
our common stock is then traded or quoted will not be effective
unless and until such approval has been obtained. The
compensation committee will not, without the further approval of
the stockholders, authorize the amendment of any outstanding
option or appreciation right to reduce the exercise price or
base price. Furthermore, no option will be cancelled and
replaced with awards having a lower exercise price without
further approval of the stockholders.
During 2006, we granted restricted stock awards to various
officers (including our named executive officers), key employees
and directors under our Equity Incentive Plan. Under these
awards, each participant received shares of our common stock
that are subject to certain transfer restrictions and risk of
forfeiture. Prior to the restrictions thereon lapsing, the
participant may not sell, transfer, pledge, assign or take any
similar action with respect to the shares of restricted stock
which the participant owns. Once the restrictions lapse with
respect to shares of restricted stock, the participant owning
such shares will hold freely-transferable shares, subject only
to any restrictions on transfer contained in our certificate of
incorporation, bylaws and insider trading policies, as well as
any applicable federal or state securities laws. Despite the
restrictions, each participant will have full voting rights and
will receive any dividends or other distributions, if any, with
respect to the shares of restricted stock which the participant
owns.
The restrictions on the restricted stock granted to our named
executive officers and non-employee directors will lapse on
July 6, 2009 and August 1, 2007, respectively.
However, the restrictions will lapse immediately upon a change
in control, upon the participants death or disability if
the participant was still employed by us or serving as one of
our directors at such time or, in the case of
Messrs. Hockema and Bellino, upon his retirement. Further,
the restrictions on the restricted stock granted to our
employees will lapse if the participants employment is
terminated by us without cause or by the participant for good
reason. If the participants employment or service as a
director should terminate for any reason other than those
described above, the participant will forfeit his or her
restricted stock award, unless the board of directors determines
all or any portion of the restricted stock grant held by the
participant will vest. In addition, under Mr. Maddoxs
employment agreement, the restrictions on his restricted stock
will lapse upon the termination of his employment (other than by
us for cause) at the conclusion of his employment agreement.
Chapter 11 Long-Term Incentive Plan
During 2002, in connection with the commencement of our
chapter 11 bankruptcy and the implementation of the
Chapter 11 KERP, we adopted our Chapter 11 Long-Term
Incentive Plan, pursuant to which key management employees,
including Messrs. Hockema, Barneson, Donnan, Maddox and
Shiba, became eligible to receive an annual cash award based on
our attainment of sustained cost reductions above
$80 million annually for the period 2002 through our
emergence from chapter 11 bankruptcy on July 6, 2006.
Under the Chapter 11 Long-Term Incentive Plan, 15% of cost
reductions above the stipulated threshold were placed in a pool
to be shared by participants based on the percentage their
individual targets comprised of the aggregate target for all
participants. Annual awards during this period ranged between
approximately (16%) to 81% of target, with an average
105
Management
award of approximately 55% of target over the four and one-half
year period. In general, approximately one-half of the award
payable under the Chapter 11 Long-Term Incentive Plan was
paid to participants in August 2006 and the remaining portion of
the award will be paid to participants on July 6, 2007,
unless the participants employment is terminated by us for
cause or is voluntarily terminated by such participant (other
than at normal retirement) prior to that date. The July 6,
2007 payments are subject to adjustment up or down to the extent
that there are fewer participants at such time or there is a
change in the size of the cost reduction pool prior to such
time. Pursuant to the terms of a release entered into between
Mr. Shiba and us in connection with his resignation, all
amounts earned by Mr. Shiba under the Chapter 11
Long-Term Incentive Plan were paid to him in early 2006.
2006 Short-Term Incentive Plan
On July 6, 2006, upon our emergence from chapter 11
bankruptcy, our compensation committee approved our 2006
Short-Term Incentive Plan for key managers. Incentive awards
under the 2006 Short-Term Incentive Plan are based upon:
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the fabricated products business
units EBITDA;
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the fabricated products business
units safety performance as measured by total case
incident rate;
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performance of the particular
business to which a participant is assigned; and
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individual performance
objectives.
|
Under the 2006 Short-Term Incentive Plan, a participant may
receive an incentive award between zero to three times the
individuals target amount.
Under the 2006 Short-Term Incentive Plan, in general, any
participant who voluntarily terminated his or her employment
(other than for good reason) or who was terminated by us for
cause prior to December 31, 2006 forfeited his or her
award. A participant will be entitled to a pro-rated award under
the 2006 Short-Term Incentive Plan if his or her employment
terminated during 2006 but prior to December 31, 2006 and
his or her employment was terminated as a result of death,
disability, normal retirement or full early retirement (position
elimination), was involuntarily terminated by us other than for
cause or was terminated by the participant for good reason. A
participant will be entitled to the full payment of his or her
award if his or her employment terminated on or after
December 31, 2006, unless such termination was by us for
cause, in which case he or she would forfeit the award.
Savings Plan
We sponsor a tax-qualified profit sharing and 401(k) plan, our
Savings Plan, in which eligible salaried employees may
participate. Pursuant to the Savings Plan, employees may elect
to reduce their current annual compensation up to the lesser of
75% or the statutorily prescribed limit of $15,500 in calendar
year 2007 (plus up to an additional $5,000 in the form of
catch-up contributions for participants near
retirement age), and have the amount of any reduction
contributed to the Savings Plan. Our Savings Plan is intended to
qualify under sections 401(a) and 401(k) of the Internal Revenue
Code, so that contributions by us or our employees to the
Savings Plan and income earned on contributions are not taxable
to employees until withdrawn from the Savings Plan and so that
contributions will be deductible by us when made. We match 100%
of the amount an employee contributes to the Savings Plan,
subject to a 4% maximum based on the employees
compensation as defined in the Savings Plan.
106
Management
Employees are immediately vested 100% in our matching
contributions to our Savings Plan. We also make annual
fixed-rate contributions on behalf of our employees in the
following amounts:
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For our employees who were
employed with us on or before January 1, 2004, we
contribute in a range from 2% to 10% of the employees
compensation, based upon the sum of the employees age and
years of continuous service as of January 1, 2004; and
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For our employees who were first
employed with us after January 1, 2004, we contribute 2% of
the employees compensation.
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An employee is required to be employed on the last day of the
year in order to receive the fixed-rate contribution. Employees
are vested 100% in our fixed-rate contributions to the Savings
Plan after five years of service. The total amount of elective,
matching and fixed-rate contributions in any year cannot exceed
the lesser of 100% of an employees compensation or $45,000
in 2007 (adjusted annually). We may amend or terminate these
matching and fixed-rate contributions at any time by an
appropriate amendment to our Savings Plan. The independent
trustee of the Savings Plan invests the assets of the Savings
Plan as directed by participants.
Chapter 11 Retention Plan
Effective September 3, 2002, in connection with the
commencement of our chapter 11 bankruptcy and the
implementation of the Chapter 11 KERP, we adopted the
Chapter 11 Retention Plan and entered into retention
agreements with selected key employees, including
Messrs. Hockema, Barneson, Donnan, Maddox and Shiba. In
general, awards payable under the Chapter 11 Retention Plan
vested, as applicable, on September 30, 2002,
March 31, 2003, September 30, 2003 and March 31,
2004. The Chapter 11 Retention Plan was not extended beyond
March 2004. Except with respect to payments of the withheld
amounts (as described below) to Messrs. Hockema and
Barneson, no payments were made after March 31, 2004 and no
further payments are payable under the Chapter 11 Retention
Plan.
For Messrs. Hockema and Barneson, $730,000 and $250,000,
respectively, of accrued awards payable under the
Chapter 11 Retention Plan were withheld for subsequent
payment. One-half of such withheld amount was paid in a lump sum
in August 2006 upon our emergence from chapter 11
bankruptcy and one-half is payable in a lump sum on July 6,
2007 unless the named executive officers employment is
terminated by us for cause or is voluntarily terminated by such
named executive officer prior to that date.
107
Management
Outstanding equity awards at December 31, 2006
The table below sets for the information regarding restricted
stock awards held by our named executive officers as of
December 31, 2006.
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Stock Awards | |
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Number of shares or units of | |
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Market value of shares or units of | |
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stock that have not vested(1) | |
|
stock that have not vested(2) | |
Name |
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(#) | |
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($) | |
| |
Jack A. Hockema
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185,000 |
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$ |
10,356,300 |
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Joseph P. Bellino
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15,000 |
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$ |
839,700 |
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John Barneson
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48,000 |
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$ |
2,687,040 |
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John M. Donnan
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45,000 |
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$ |
2,519,100 |
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Daniel D. Maddox
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11,334 |
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$ |
634,477 |
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Kerry A. Shiba
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(1) |
Reflects the number of shares of restricted stock received by
our named executive officers pursuant to awards granted under
our Equity Incentive Plan on July 6, 2006 in connection
with our emergence from chapter 11 bankruptcy. The
restrictions on all such shares will lapse on July 6, 2009
or earlier if the named executive officers employment
terminates as a result of death or disability (or, in the case
of Messrs. Hockema and Bellino, retirement), the named
executive officers employment is terminated by us without
cause, the named executive officers employment is
voluntarily terminated by him for good reason or if there is a
change in control or, in the case of Mr. Maddox, his employment
is terminated (other than by us for cause) upon the conclusion
of his employment agreement. Mr. Shiba, who resigned
effective January 23, 2006, did not receive a restricted
stock award. |
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(2) |
Reflects the aggregate market value of the shares of
restricted stock determined based on a per share price of
$55.98, the reported closing price for our common stock on the
Nasdaq Global Market on December 29, 2006, which was the
last trading day of 2006. |
108
Management
Pension benefits as of December 31, 2006
The table below sets forth information regarding the present
value as of December 31, 2006 of the accumulated benefits
of our named executive officers (other than Mr. Bellino) under
our Old Pension Plan. As discussed further below, our Old
Pension Plan was terminated on December 17, 2003, at which
time the number of years of credited service for participants
was frozen. Mr. Bellino joined us in May 2006 and did not
participate in the Old Pension Plan prior to its termination.
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Present value of | |
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Number of years | |
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accumulated | |
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|
credited service | |
|
benefit(1) | |
Name |
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Plan name | |
|
(#) | |
|
($) | |
| |
Jack A. Hockema
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Kaiser Aluminum Salaried |
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|
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Employees Retirement Plan |
|
|
|
11.92 |
|
|
$ |
293,262 |
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John Barneson
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Kaiser Aluminum Salaried |
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|
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|
|
|
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|
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Employees Retirement Plan |
|
|
|
28.83 |
|
|
$ |
269,372 |
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John M. Donnan
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Kaiser Aluminum Salaried |
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Employees Retirement Plan |
|
|
|
10.25 |
|
|
$ |
129,390 |
|
|
Daniel D. Maddox
|
|
|
Kaiser Aluminum Salaried |
|
|
|
|
|
|
|
|
|
|
|
|
Employees Retirement Plan |
|
|
|
7.58 |
|
|
$ |
94,867 |
|
|
Kerry A. Shiba
|
|
|
Kaiser Aluminum Salaried |
|
|
|
|
|
|
|
|
|
|
|
|
Employees Retirement Plan |
|
|
|
5.58 |
|
|
$ |
91,016 |
|
|
|
(1) |
Reflects the actuarial present value of the named executive
officers accumulated benefit under our Old Pension Plan at
December 31, 2006 determined (a) assuming mortality
according to the
RP-2000 Combined Health
mortality table published by the Society of Actuaries and
(b) applying a discount rate of 5.75% per annum. |
The Old Pension Plan previously maintained by us was a
qualified, defined-benefit retirement plan for our salaried
employees who met certain eligibility requirements. Effective
December 17, 2003, the PBGC terminated and effectively
assumed responsibility for making benefit payments in respect of
the Old Pension Plan. As a result of the termination, all
benefit accruals under the Old Pension Plan were terminated and
benefits available to certain executive officers, including
Messrs. Hockema and Barneson, were significantly reduced
due to the limitation on benefits payable by the PBGC. Benefits
payable to participants will be reduced to a maximum of $34,742
annually for retirement at age 62, a lower amount for retirement
prior to age 62, and a higher amount for retirements after age
62, up to $43,977 at age 65, and participants will not accrue
additional benefits. In addition, the PBGC will not make
lump-sum payments to participants.
109
Management
Nonqualified deferred compensation for 2006
The table below sets forth, for each of our named executive
officers, information regarding his participation in our New
Restoration Plan during 2006.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Registrant | |
|
Aggregate | |
|
Aggregate | |
|
|
contributions | |
|
earnings in | |
|
balance at | |
Name |
|
in last FY(1) | |
|
last FY(2) | |
|
last FYE(3) | |
| |
Jack A. Hockema
|
|
$ |
105,037 |
|
|
$ |
26,051 |
|
|
$ |
1,095,806 |
|
|
Joseph P. Bellino
|
|
|
|
|
|
|
|
|
|
|
|
|
|
John Barneson
|
|
$ |
27,873 |
|
|
$ |
19,102 |
|
|
$ |
934,341 |
|
|
John M. Donnan
|
|
$ |
9,809 |
|
|
$ |
7,359 |
|
|
$ |
72,018 |
|
|
Daniel D. Maddox
|
|
$ |
5,579 |
|
|
$ |
1,144 |
|
|
$ |
48,140 |
|
|
Kerry A. Shiba
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
In each case, 100% of such amount is included in the
All Other Compensation column of the summary
compensation table above. See Summary Compensation
table for 2006. |
|
(2) |
Amounts included in this column do not include above-market
or preferential earnings (of which there were none) and,
accordingly, such amount is not included in the Change in
Pension Value and Nonqualified Deferred Compensation
Earnings column of the summary compensation table above.
See Summary Compensation table for 2006. |
|
(3) |
Includes amounts accrued under the Old Restoration Plan and
transferred to accounts under the New Restoration Plan upon its
adoption in connection with our emergence from chapter 11
bankruptcy, as follows: Mr. Hockema, $964,718;
Mr. Barneson, $887,366; Mr. Donnan, $54,851; and
Mr. Maddox, $41,416. Mr. Shiba, who resigned effective
January 23, 2006, did not participate in the New
Restoration Plan and, accordingly, the amount of benefits
accrued to him under the Old Restoration Plan was not
transferred to the New Restoration Plan. Mr. Bellino, who
joined us in May 2006, did not participate in the New
Restoration Plan in 2006. |
The New Restoration Plan is a plan we sponsor in which a select
group of our management and highly compensated employees may
participate. Eligibility to participate in our New Restoration
Plan is determined by the compensation committee, which
currently administers the New Restoration Plan. The purpose of
our New Restoration Plan is to restore the benefit of matching
and fixed-rate contributions that we would have otherwise paid
to participants under our Savings Plan but for the limitations
on benefit accruals and payments imposed by the Internal Revenue
Code. We maintain an account on behalf of each participant in
the New Restoration Plan and contributions to a
participants New Restoration Plan account to restore
benefits under the Savings Plan are made generally in the manner
described below:
|
|
|
If our matching contributions to
a participant under the Savings Plan are limited in any year, we
will make an annual contribution to that participants
account under the New Restoration Plan equal to the difference
between:
|
|
|
|
|
- |
the matching contributions that we could have made to that
participants account under the Savings Plan if the
Internal Revenue Code did not impose any limitations; and |
|
|
- |
the maximum contribution we could in fact make to that
participants account under the Savings Plan in light of
the limitations imposed by the Internal Revenue Code. |
110
Management
|
|
|
A participant is required to be making elective contributions
under our Savings Plan on the first day of the year in order to
receive a matching contribution from us under our New
Restoration Plan for that year. However, matching contributions
under the New Restoration Plan are calculated as though the
participant elected to make the maximum permissible elective
contributions under the Savings Plan sufficient to receive the
maximum matching contribution from us under the Savings Plan,
without regard for the participants actual elective
contributions. Participants are immediately vested 100% in our
matching contributions to the New Restoration Plan. |
|
|
Annual fixed-rate contributions to the participants
account under the New Restoration Plan are made in an amount
equal to between 2% and 10% of the participants excess
compensation, as defined in Section 401(a)(17) of the
Internal Revenue Code. The actual fixed-rate contribution
percentage is determined based upon the sum of the
participants age and years of continuous service as of
January 1, 2004. If a participant is first employed with us
after January 1, 2004, the fixed-rate contribution
percentage is 2%. A participant is required to be employed on
the last day of the year in order to receive the fixed-rate
contribution. Further, to the extent that fixed-rate
contributions to a participant under our Savings Plan on
compensation that is not excess compensation, as defined in
Internal Revenue Code Section 401(a)(17), cannot be made
under the Savings Plan due to Internal Revenue Code limitations,
such fixed-rate contributions will be made to such
participants account under our New Restoration Plan.
Participants are vested 100% in our fixed-rate contributions to
our New Restoration Plan after five years of service or upon
retirement, death, disability or a change of control. |
A participant is entitled to distributions six months following
his or her termination of service, except that any participant
who is terminated for cause will forfeit the entire amount of
matching and fixed-rate contributions made by us to that
participants account under the New Restoration Plan.
The Restoration Plan was deemed effective as of May 1,
2005, the date on which the accrual of benefits under the Old
Restoration Plan was terminated. The lump-sum actuarial
equivalent amount of the benefit accrued to a participant under
the Old Restoration Plan has been transferred to such
participants account under the New Restoration Plan.
We may amend or terminate these matching and fixed-rate
contributions at any time by an appropriate amendment to our New
Restoration Plan. The value of each participants account
under our New Restoration Plan changes based upon the
performance of the funds designated by the participant from a
menu of various money market and investment funds.
111
Management
Potential payments and benefits upon termination of
employment
This section sets forth for each named executive officer (other
than Mr. Shiba) quantitative disclosure regarding estimated
payments and other benefits that would have been received by the
named executive officer or his estate if his employment had
terminated on December 29, 2006, the last business day of
2006, under the following circumstances:
|
|
|
voluntary termination by the
named executive officer;
|
|
|
termination by us for cause;
|
|
|
termination by us without cause
or by the named executive officer with good reason;
|
|
|
termination by us without cause
or by the named executive officer with good reason following a
change in control;
|
|
|
termination at normal retirement;
|
|
|
termination as a result of
disability; or
|
|
|
termination as a result of death.
|
Mr. Shiba, who resigned effective January 23, 2006,
was not serving as one of our executive officers at the end of
2006 and, in lieu of all benefits to which Mr. Shiba might
otherwise have been entitled and in consideration of his
satisfaction of certain post-termination obligations,
Mr. Shiba received payments in accordance with the terms of
the release entered into by him and us in connection with his
resignation. See Employment-related agreements and certain
employee benefit plans Release with Kerry A.
Shiba for a more detailed discussion of such payments.
112
Management
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
JACK A. HOCKEMA | |
| |
|
|
Circumstances of Termination | |
|
|
| |
|
|
|
|
Termination | |
|
|
|
|
|
|
by us without | |
|
|
|
|
|
|
Termination | |
|
cause or by | |
|
|
|
|
|
|
by us without | |
|
the named | |
|
|
|
|
|
|
cause or by | |
|
executive | |
|
|
|
|
Voluntary | |
|
|
|
the named | |
|
officer with | |
|
|
|
|
termination | |
|
|
|
executive | |
|
good reason | |
|
|
|
|
by named | |
|
Termination | |
|
officer with | |
|
following a | |
|
Normal | |
|
|
Payments and benefits |
|
executive officer | |
|
by us for cause | |
|
good reason | |
|
change in control | |
|
retirement | |
|
Disability | |
|
Death | |
| |
Payment of earned but unpaid:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Base
salary(1)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-term
incentive(2)
|
|
|
|
|
|
|
|
|
|
$ |
1,649,440 |
|
|
$ |
1,649,440 |
|
|
$ |
1,649,440 |
|
|
$ |
1,649,440 |
|
|
$ |
1,649,440 |
|
|
Short-term
incentive(3)
|
|
|
|
|
|
|
|
|
|
$ |
497,310 |
|
|
$ |
497,310 |
|
|
$ |
497,310 |
|
|
$ |
497,310 |
|
|
$ |
497,310 |
|
|
Retention
payment(4)
|
|
|
|
|
|
|
|
|
|
$ |
365,000 |
|
|
$ |
365,000 |
|
|
$ |
365,000 |
|
|
$ |
365,000 |
|
|
$ |
365,000 |
|
|
Vacation(5)
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
|
$ |
56,154 |
|
Other benefits:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Lump-sum payment
|
|
|
|
|
|
|
|
|
|
$ |
2,460,100 |
(6) |
|
$ |
3,690,150 |
(7) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Healthcare benefits
|
|
|
|
|
|
|
|
|
|
$ |
29,880 |
(8) |
|
$ |
45,474 |
(8) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Disability benefits
|
|
|
|
|
|
|
|
|
|
$ |
13,450 |
(9) |
|
$ |
18,212 |
(9) |
|
|
|
|
|
$ |
710,856 |
(10) |
|
|
|
|
|
Life insurance
|
|
|
|
|
|
|
|
|
|
|
|
(11) |
|
|
|
(11) |
|
|
|
|
|
|
|
|
|
|
|
(12) |
|
Perquisites and other personal benefits
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Tax
gross-up(13)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$ |
4,393,426 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Acceleration of stock awards:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Market value of stock vesting on
termination(14)
|
|
|
|
|
|
|
|
|
|
$ |
10,356,300 |
|
|
$ |
10,356,300 |
|
|
$ |
10,356,300 |
|
|
$ |
10,356,300 |
|
|
$ |
10,356,300 |
|
Distribution of New Restoration Plan balance:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Amount of distribution
(15)
|
|
$ |
1,095,806 |
|
|
$ |
|
|
|
$ |
1,095,806 |
|
|
$ |
1,095,806 |
|
|
$ |
1,095,806 |
|
|
$ |
1, 095,806 |
|
|
$ |
1,095,806 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
$ |
1,151,960 |
|
|
$ |
56,154 |
|
|
$ |
16,523,440 |
|
|
$ |
22,167,272 |
|
|
$ |
14,020,010 |
|
|
$ |
14,730,866 |
|
|
$ |
14,020,010 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
Assumes that there is no earned but unpaid base salary at the
time of termination. |
|
(2) |
Under our Chapter 11 Long-Term Incentive Plan, we must
pay Mr. Hockema or his estate the remaining portion of the
total amount accrued by Mr. Hockema thereunder on July 6,
2007 unless he is terminated by us for cause or he voluntarily
terminates his employment (other than at normal retirement)
prior to that date. The $1,649,440 amount reflected in the table
is based on computations made in connection with the 2006
payments under the Chapter 11 Long-Term Incentive Plan and
assumes no decrease in the number of plan participants or
adjustment to the cost reduction pool prior to July 6,
2007. |
|
(3) |
Under our 2006 Short-Term Incentive Plan,
Mr. Hockemas target award for 2006 is $500,050, but
his award can range from a threshold of $250,000 to a maximum of
$1,500,150, or could be zero if the threshold performance is not
achieved. The exact amount of Mr. Hockemas award
under our 2006 Short-Term Incentive Plan cannot be determined at
this time. Pursuant to |
(footnotes continued on following page)
113
Management
|
|
|
Mr. Hockemas employment agreement, we must pay
Mr. Hockema or his estate any earned but unpaid amounts
under our 2006 Short-Term Incentive Plan unless he is terminated
by us for cause or he voluntarily terminates his employment
other than for good reason. Under Mr. Hockemas
employment agreement, if his employment had terminated during
2006 but prior to December 31, 2006 Mr. Hockemas
target award for 2006 under our 2006 Short-Term Incentive Plan
would have been prorated for the actual number of days of
Mr. Hockemas employment in 2006 and Mr. Hockema
would have been entitled to payment of such amount, without any
increase or reduction that would normally be considered with his
award, unless his employment had been terminated by us for cause
or had been voluntarily terminated by him other than for good
reason; accordingly, assuming his employment had terminated on
December 29, 2006, the last business day of 2006, we would
have been obligated to pay Mr. Hockema $497,310 unless his
employment had been terminated by us for cause or had been
voluntarily terminated by him other than for good reason. Under
Mr. Hockemas employment agreement, if his employment
had terminated on December 31, 2006, the last day of our
2006 fiscal year, Mr. Hockema would have been entitled to
full payment of his award under the 2006 Short-Term Incentive
Plan unless his employment had been terminated by us for cause
or had been voluntarily terminated by him other than for good
reason. Solely for purposes of this note, we estimate that
Mr. Hockemas award under our 2006 Short-Term
Incentive Plan will be between $750,075 and $1,250,125 (with a
midpoint of $1,000,000), before taking into account any
adjustments for individual performance or applicable modifiers.
We believe this is a reasonable estimate of the potential range
of Mr. Hockemas award based on our results through
the third quarter of 2006. |
|
(4) |
Under our Chapter 11 Retention Plan, we must pay
Mr. Hockema or his estate $365,000 on July 6, 2007
unless his employment is terminated by us for cause or is
voluntarily terminated by him (other than at normal retirement)
prior to that date. |
|
(5) |
Assumes that Mr. Hockema used all of his 2006 vacation and
that he has four weeks of accrued vacation for 2007. |
|
(6) |
Under Mr. Hockemas employment agreement, if
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him for good reason, we
must make a lump-sum payment to Mr. Hockema in an amount
equal to two times the sum of his base salary and target annual
bonus opportunity for the fiscal year in which such termination
occurs. |
|
(7) |
Under Mr. Hockemas employment agreement, if
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him for good reason within
two years following a change in control, we must make a lump-sum
payment to Mr. Hockema in an amount equal to three times
the sum of his base salary and target annual bonus. |
|
(8) |
Under Mr. Hockemas employment agreement, if
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him for good reason, we
must continue his medical and dental benefits for two years, or,
if such termination occurs within two years following a change
in control, three years, commencing on the date of such
termination. The table reflects the present value of such
medical and dental benefits at December 29, 2006 determined
(a) assuming family coverage in a point of service medical
plan and a basic dental plan, (b) based on current COBRA
coverage rates for 2007 and assuming a 9% increase in the cost
of medical coverage for 2008 as compared to 2007, an 8.5%
increase in the cost of medical coverage for 2009 as compared to
2008 and a 6% increase in the cost of dental coverage for 2008
as compared to 2007 and for 2009 as compared to 2008, (c)
assuming Mr. Hockema pays premiums for such coverage
throughout the applicable benefit continuation period in the
same manner as if he were an active employee, and
(d) applying a discount rate of 5.75% per annum. |
|
(9) |
Under Mr. Hockemas employment agreement, if
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him for good reason, we
must continue his disability benefits for two years, or, if such
termination occurs within two years following a change in
control, three years, commencing on the date of such
termination. The table reflects |
(footnotes continued on following page)
114
Management
|
|
|
the present value of such disability benefits at
December 29, 2006 determined (a) based on our current
costs of providing such benefits and assuming such costs do not
increase during the applicable benefit continuation period,
(b) assuming we pay such costs throughout the applicable
benefit continuation period in the same manner as we currently
pay such costs, (c) assuming mortality according to the
RP-2000 Combined Health mortality table published by the Society
of Actuaries, and (d) applying a discount rate of 5.75% per
annum. |
|
|
(10) |
Reflects the actuarial present value of
Mr. Hockemas disability benefits at December 29,
2006 determined (a) assuming full disability at December
29, 2006, (b) assuming mortality according to the RP-2000
Disabled Retiree mortality table published by the Society of
Actuaries, and (c) applying a discount rate of 5.75% per
annum. |
|
|
(11) |
Under Mr. Hockemas employment agreement, if
Mr. Hockemas employment is terminated by us without
cause or is voluntarily terminated by him for good reason, we
must continue his life insurance benefits for two years, or, if
such termination occurs within two years following a change in
control, three years, commencing on the date of such
termination. Mr. Hockema has declined life insurance coverage.
Accordingly, we would not be obligated to provide
Mr. Hockema with life insurance benefits for the applicable
benefit continuation period. |
|
|
|
(12) |
No life insurance benefit would have been payable assuming
Mr. Hockemas death occurred on December 29, 2006
other than while traveling on company-related business. However,
we maintain a travel and accidental death policy for certain
employees, including Mr. Hockema, that would provide a
$1,000,000 death benefit payable to Mr. Hockemas
estate if his death had occurred during company-related
travel. |
|
|
(13) |
Under Mr. Hockemas employment agreement, if any
payments to Mr. Hockema would be subject to federal excise
tax by reason of being considered contingent on a change in
control, we must pay to Mr. Hockema an additional amount
such that, after satisfaction of all tax obligations imposed on
such payments, Mr. Hockema retains an amount equal to such
federal excise tax. The table reflects an estimate of the
additional amount that we would have been obligated to pay
Mr. Hockema if his employment had been terminated on
December 29, 2006 by us without cause or by him with good
reason following a change in control on such date. |
|
(14) |
Reflects the aggregate market value of the shares of
restricted stock for which restrictions would lapse early due to
Mr. Hockemas termination, determined based on a per
share price of $55.98, the reported closing price for our common
stock on the Nasdaq Global Market on December 29, 2006,
which was the last trading day of 2006. The restrictions on all
shares of restricted stock currently held by Mr. Hockema
will lapse on July 6, 2009 or earlier if his employment
terminates as a result of his death, disability or retirement,
his employment is terminated by us without cause or his
employment is voluntarily terminated by him for good reason, or
if there is a change in control. |
|
(15) |
Under our New Restoration Plan, Mr. Hockema is entitled
to a distribution of his account balance six months following
his termination, except that he will forfeit the entire amount
of matching and fixed rate contributions made by us to his
account if he is terminated for cause. |
115
Management